A monitoring device for the grease state of a wind turbine main bearing

Abstract

The utility model discloses a kind of monitoring devices applied in wind power main bearing grease state, it is related to grease multi-parameter monitoring device field.The utility model includes monitoring sensor, the monitoring sensor is connected with the outer surface of the middle lower part of main bearing by forced transport mechanism and moves, for the lubricating grease of the middle lower part inside main bearing is forced to transport and passes through the monitoring end of monitoring sensor, the utility model is forced to transport mechanism, driving mechanism is rotated by sprocket and chain drive helical blade in first installation cylinder, lubricating grease deposited in the lower part raceway of main bearing is forced to transport to first installation cylinder by through-hole, directly solve the uneven distribution problem of lubricating grease due to gravity deposition, poor circulation, ensure that monitoring sensor can contact representative lubricating grease sample, by continuously updating lubricating grease sample flowing through sensor, eliminate the monitoring data lag caused by long-term deposition, significantly improve the timeliness of fault early warning.

Description

Technical Field

[0001] This utility model relates to the field of multi-parameter monitoring devices for lubricating grease, specifically a monitoring device for the condition of lubricating grease in wind turbine main bearings. Background Technology

[0002] Electrochemical sensors for wind turbine main bearing grease, such as the CANCIESXUV1AJ grease sensor, can directly detect key indicators such as temperature, dielectric constant, conductivity, and moisture content to achieve real-time assessment and fault warning of grease condition. This can provide early warning of bearing wear several months in advance, extend the grease replacement cycle by 30%-50%, and reduce the risk of unplanned downtime.

[0003] Current multi-parameter grease sensors can monitor the condition of lubricating grease inside wind turbine main bearings, thereby improving the monitoring effect and maintenance convenience. However, a problem exists in actual use: due to the large number of grease cavities inside the main bearing, the grease distribution is uneven. Due to gravity, a large amount of grease deposits at the bottom of the internal cavities. When monitoring these areas with poor grease flow, the multi-parameter grease sensor with a fixed installation position suffers from poor monitoring accuracy. Therefore, the inventors urgently need to design a sensor that can improve the flow rate of grease in the lower raceway of the main bearing, thereby improving the monitoring accuracy of the main bearing. Utility Model Content

[0004] Based on this, the purpose of this utility model is to provide a monitoring device for the condition of grease in wind turbine main bearings, so as to solve the technical problem of sensor inaccuracy caused by uneven distribution of grease in wind turbine main bearings.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a monitoring device for the condition of grease in wind turbine main bearings, comprising a monitoring sensor, wherein the monitoring sensor is movably connected to the lower outer surface of the main bearing via a forced conveying mechanism, for forcibly conveying the grease in the lower middle part of the main bearing through the monitoring end of the monitoring sensor;

[0006] The forced conveying mechanism includes a first mounting cylinder and a second mounting cylinder fixedly connected along parallel axes. A grease circulation guide groove is formed inside the two mounting cylinders. A sensor mounting position is provided on the second mounting cylinder. The first mounting cylinder and the second mounting cylinder are separated by a partition with a guide groove. A helical blade is coaxially arranged inside the first mounting cylinder. The helical blade is provided with rotational power by an external drive mechanism to realize the forced circulation of grease in the raceway of the main bearing.

[0007] By adopting the above technical solution, the linkage between the forced delivery mechanism and the monitoring sensor effectively solves the problem of inaccurate monitoring caused by grease deposition in the lower part of the main bearing. The forced delivery mechanism uses a first mounting cylinder and a second mounting cylinder connected by parallel axes, where the axis is the central axis of the first mounting cylinder and the second mounting cylinder. This ensures that the first mounting cylinder and the second mounting cylinder are fixed in parallel and form an effective grease flow path. A continuous grease circulation guide groove is formed inside. Combined with the rotational power of the spiral blades, the grease deposited in the lower part of the bearing can be actively and forcibly delivered to the detection area of ​​the monitoring sensor, which significantly improves the sensor's ability to capture the grease status in key areas.

[0008] By adopting the above technical solution, the interference fit between the outer shell of the main bearing and the outer ring of the main bearing enhances the structural rigidity and sealing performance of the bearing assembly, effectively preventing external contaminants from entering the lubrication system and reducing the risk of grease deterioration due to seal failure.

[0009] Furthermore, the first and second mounting cylinders are fixed to the outer ring of the main bearing by a sealed welding method, and the grease circulation channels inside the two mounting cylinders are connected to the raceway of the main bearing through axial through holes to form a closed loop.

[0010] By adopting the above technical solution, the first mounting cylinder and the second mounting cylinder are fixed to the outer ring of the main bearing by sealing welding, eliminating the potential leakage hazards of traditional flange connections and ensuring the airtightness of the grease circulation channel.

[0011] Furthermore, the drive mechanism includes a servo motor, a sprocket, and a chain. The servo motor drive end drives the central shaft of the spiral blade through a chain transmission system, and the servo motor control end is connected to a PLC controller.

[0012] By adopting the above technical solution, the drive mechanism uses a servo motor in conjunction with a sprocket and chain transmission scheme, which can accurately control the speed and torque output of the spiral blades, adapt to the dynamic changes in the viscosity of the lubricating grease under different working conditions, and ensure the efficiency and stability of forced delivery.

[0013] Furthermore, the end of the second mounting cylinder is provided with a mounting interface, which is adapted to the probe housing of the monitoring sensor through a threaded sealing structure.

[0014] By adopting the above technical solution, the installation interface adopts a threaded sealing structure, which realizes the rapid installation and reliable sealing of the monitoring sensor and the forced conveying mechanism, and avoids grease leakage that contaminates the sensor's electronic components.

[0015] Furthermore, the monitoring end of the monitoring sensor is connected to a rigid mounting sleeve rod, which passes through the second mounting cylinder and extends into the raceway of the main bearing. A temperature sensing harness is integrated inside the sleeve rod, and the temperature sensing harness and the mounting sleeve rod form a sealed assembly structure.

[0016] By adopting the above technical solution, a physical protective barrier is provided for the temperature sensing harness, preventing cable damage caused by the impact of lubricating grease flow or friction of metal particles. At the same time, the sealed assembly structure of the mounting sleeve and the temperature sensing harness isolates the sensing element from external moisture and dust, ensuring the long-term accuracy of temperature data.

[0017] Furthermore, the monitoring sensor is connected to the data acquisition unit via an RS485 bus, and the data acquisition unit uploads data on grease viscosity, metal particle concentration, and temperature to a cloud server via a 4G module.

[0018] By adopting the above technical solution and utilizing the anti-interference characteristics of industrial-grade communication protocols, the transmission stability of lubricating grease status data is ensured in complex electromagnetic environments. At the same time, the data acquisition unit uploads viscosity, metal particle concentration, and temperature parameters to the cloud server via a 4G module, realizing centralized monitoring and cross-platform data sharing of multiple wind farm units and supporting collaborative analysis of lubrication status by remote expert systems.

[0019] In summary, the present invention has the following main advantages:

[0020] This invention utilizes a forced conveying mechanism. The drive mechanism, via a sprocket and chain, rotates the spiral blades inside the first mounting cylinder, forcibly conveying the grease deposited in the lower raceway of the main bearing through a through-hole to the first mounting cylinder. This directly solves the problem of uneven grease distribution caused by gravity deposition and poor flowability, ensuring that the monitoring sensor can contact a representative grease sample. Simultaneously, as the grease flows through the second mounting cylinder, the probe of the monitoring sensor synchronously detects the grease's conductivity and dielectric constant, while the temperature monitoring harness embedded in the mounting sleeve collects the grease temperature in real time, achieving comprehensive monitoring of multiple parameters and providing comprehensive data support for the bearing's health status. Furthermore, the detected grease returns to the main bearing raceway through a closed-loop channel, forming a dynamic circulation system. This avoids localized grease retention or excessive consumption caused by traditional static monitoring. This circulation mechanism not only maintains the stability of the total amount of grease inside the bearing but also eliminates monitoring data lag caused by long-term deposition by continuously updating the grease sample flowing through the sensor, significantly improving the timeliness of fault early warning.

[0021] This invention utilizes a rigid mounting sleeve, whose through-type design allows it to extend stably into the raceway of the main bearing, directly contacting the grease working area. This ensures that the detection end of the temperature monitoring harness is accurately positioned on the grease flow path, avoiding data deviations caused by external housing temperature interference. At the same time, the rigid structure resists high-frequency vibrations and mechanical shocks during main bearing operation, protecting the internal temperature sensing harness from physical damage and maintaining long-term monitoring stability. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0023] Figure 2 This is a cross-sectional structural diagram of the present invention;

[0024] Figure 3 This utility model Figure 2 A magnified structural diagram of point A in the middle.

[0025] In the diagram: 101, outer ring of main bearing; 2, forced conveying mechanism; 201, first mounting cylinder; 202, second mounting cylinder; 203, partition plate; 204, spiral blade; 205, mounting interface; 206, guide groove; 3, monitoring sensor; 4, mounting sleeve rod; 5, drive mechanism; 501, sprocket; 502, chain; 503, servo motor. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0027] Example 1:

[0028] A monitoring device for the condition of lubricating grease in wind turbine main bearings, such as Figures 1-3 As shown, it includes a monitoring sensor 3, which is movably connected to the lower outer surface of the main bearing via a forced conveying mechanism 2, and is used to forcibly convey the grease in the lower middle part of the main bearing and pass it through the monitoring end of the monitoring sensor 3.

[0029] The forced conveying mechanism 2 includes a first mounting cylinder 201 and a second mounting cylinder 202 that are coaxially fixedly connected. The two mounting cylinders form a connected grease circulation guide groove inside. The second mounting cylinder 202 is provided with a sensor mounting position. The first mounting cylinder 201 and the second mounting cylinder 202 are separated by a partition 203 with a guide groove 206. A spiral blade 204 is coaxially arranged inside the first mounting cylinder 201. The spiral blade 204 is provided with rotational power by an external drive mechanism 5 to realize the forced circulation of grease in the raceway of the main bearing.

[0030] The linkage between the forced delivery mechanism 2 and the monitoring sensor 3 effectively solves the problem of inaccurate monitoring caused by grease deposition in the lower part of the main bearing. The forced delivery mechanism 2 uses a first mounting cylinder 201 and a second mounting cylinder 202 connected by parallel axes, forming a continuous grease circulation guide groove inside. Combined with the rotational power of the spiral blade 204, it can actively and forcibly deliver the grease deposited in the lower part of the bearing to the detection area of ​​the monitoring sensor 3, significantly improving the sensor's ability to capture the grease status in key areas. At the same time, the guide groove 206 on the partition 203 optimizes the flow path of the grease, avoids turbulence interference, and ensures the flow stability and data consistency of the grease during the detection process, providing a reliable basis for bearing health assessment.

[0031] See Figure 1 , Figure 2 , Figure 3 The first mounting cylinder 201 and the second mounting cylinder 202 are fixed to the outer ring 101 of the main bearing by a sealed welding method and extend to the inner side of the outer ring 101 of the main bearing. The grease circulation channel inside the two mounting cylinders forms a closed loop with the raceway of the main bearing through the axial through hole. The first mounting cylinder 201 and the second mounting cylinder 202 are fixed to the outer ring 101 of the main bearing by a sealed welding method, which eliminates the leakage hazards that may exist in traditional flange connections and ensures the airtightness of the grease circulation channel. At the same time, the two mounting cylinders form a closed loop with the raceway of the main bearing through the axial through hole, so that the grease that is forcibly delivered can flow back to the bearing working area after the test is completed, realizing the continuous renewal and recycling of grease and avoiding grease loss caused by forced delivery.

[0032] See Figure 1 , Figure 2 , Figure 3 The drive mechanism 5 includes a servo motor 503, a sprocket 501, and a chain 502. The drive end of the servo motor 503 drives the central shaft of the spiral blade 204 to rotate through the chain transmission system. That is, both the drive end of the servo motor 503 and the end of the central shaft of the spiral blade 204 are equipped with sprockets 201, and the two sprockets 201 are driven by the sprocket 501. The control end of the servo motor 503 is connected to the PLC controller. The drive mechanism 5 adopts a transmission scheme of servo motor 503 in combination with sprocket 501 and chain 502, which can accurately control the speed and torque output of the spiral blade 204, adapt to the dynamic changes of the conductivity and dielectric constant of the grease under different working conditions, and ensure the efficiency and stability of forced delivery. At the same time, the linkage between the servo motor 503 and the PLC controller supports real-time adjustment of the drive strategy according to parameters such as bearing speed and temperature. For example, the speed of the spiral blade 204 can be increased in low-speed conditions to enhance the forced delivery force, or the speed can be reduced in high-temperature conditions to avoid overheating and deterioration of the grease.

[0033] See Figure 1 , Figure 2 , Figure 3 The second mounting cylinder 202 has a mounting interface 205 at its end. The mounting interface 205 is adapted to the probe housing of the monitoring sensor 3 through a threaded sealing structure. The mounting interface 205 adopts a threaded sealing structure, which realizes the quick installation and reliable sealing of the monitoring sensor 3 and the forced conveying mechanism 2, and avoids grease leakage and contamination of the sensor's electronic components. At the same time, the threaded connection allows the monitoring sensor 3 to be replaced or calibrated without disassembling the main bearing housing, which significantly simplifies the maintenance process, reduces equipment downtime, and enhances the adaptability and functional expandability of the device. The monitoring sensor 3 adopts the JCQM-6900 multi-parameter oil sensor, which integrates the monitoring of key parameters such as temperature, viscosity, dielectric constant, moisture and metal particles.

[0034] Example 2:

[0035] See Figure 1 , Figure 2 , Figure 3 The monitoring end of the monitoring sensor 3 is connected to a rigid mounting sleeve 4. The mounting sleeve 4 passes through the second mounting cylinder 202 and extends into the main bearing raceway. A temperature sensing harness is integrated inside the sleeve. The temperature sensing harness and the mounting sleeve 4 form a sealed assembly structure, providing a physical protective barrier for the temperature sensing harness and preventing cable damage caused by grease flow impact or metal particle friction. At the same time, the sealed assembly structure of the mounting sleeve 4 and the temperature sensing harness isolates the sensing element from external moisture and dust corrosion, ensuring the long-term accuracy of temperature data. In addition, the layout of the sleeve end extending into the bearing raceway makes the temperature monitoring point closer to the actual working area of ​​the grease, which can reflect the raceway frictional heat effect in real time and provide direct data support for early warning of abnormal temperature rise.

[0036] Monitoring sensor 3 communicates with the data acquisition unit via an RS485 bus. The data acquisition unit uploads the grease conductivity, dielectric constant, and temperature data to the cloud server via a 4G module. Utilizing the anti-interference characteristics of industrial-grade communication protocols, the transmission stability of grease status data is ensured in complex electromagnetic environments. Simultaneously, the data acquisition unit uploads grease conductivity, dielectric constant, and temperature parameters to the cloud server via the 4G module, enabling centralized monitoring and cross-platform data sharing of multiple wind farm units. This supports collaborative analysis of lubrication status by remote expert systems. Furthermore, cloud data storage provides a foundation for historical trend analysis and the construction of a fault mode database, which helps optimize lubrication maintenance strategies through machine learning algorithms, promoting the upgrade of monitoring modes from passive response to predictive maintenance.

[0037] The implementation principle of this embodiment is as follows: During monitoring, the drive mechanism 5 drives the spiral blade 204 inside the first mounting cylinder 201 to rotate through the sprocket 501 and chain 502, forcibly conveying the grease deposited in the lower raceway of the main bearing to the first mounting cylinder 201 through the through hole; the grease passes through the through groove 206 of the partition 203 and enters the second mounting cylinder 202. While flowing through the second mounting cylinder 202, the monitoring sensor 3 detects the conductivity and dielectric constant of the flowing grease through the probe, and the monitoring end of the temperature monitoring harness embedded in the mounting sleeve rod 4 collects the grease temperature in real time; the detected grease returns to the main bearing raceway through the closed-loop channel, forming a dynamic cycle. The monitoring data is uploaded to the SCADA system through RS485 communication to realize real-time evaluation of the bearing operating status;

[0038] In some other embodiments: the drive mechanism 5 is mounted on an external support frame, has a stable mounting structure, and does not have direct contact with the main bearing, but only transmits torque to the helical blade 204.

[0039] Although embodiments of the present invention have been shown and described, these specific embodiments are merely explanations of the present invention and are not intended to limit the invention. The specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions, and variations to the embodiments as needed without departing from the principles and spirit of the present invention, provided that such modifications, substitutions, and variations are within the scope of the claims of the present invention and are protected by patent law.

Claims

1. A monitoring device for the condition of lubricating grease in wind turbine main bearings, characterized in that: Includes a monitoring sensor (3), which is movably connected to the outer surface of the main bearing via a forced conveying mechanism (2) to forcibly convey the grease in the lower middle part of the main bearing through the monitoring end of the monitoring sensor (3); The forced conveying mechanism (2) includes a first mounting cylinder (201) and a second mounting cylinder (202) fixedly connected to each other along parallel axes. The first mounting cylinder (201) and the second mounting cylinder (202) form a connected grease circulation guide groove inside. The second mounting cylinder (202) has a sensor mounting position on the side away from the wind turbine main bearing. The first mounting cylinder (201) and the second mounting cylinder (202) are separated by a partition (203) with a guide groove (206). The first mounting cylinder (201) is provided with a spiral blade (204). The spiral blade (204) is provided with rotational power by an external drive mechanism (5) to realize the circulation of grease in the raceway of the main bearing.

2. The monitoring device for the condition of lubricating grease in wind turbine main bearings according to claim 1, characterized in that: The first mounting cylinder (201) and the second mounting cylinder (202) are fixed to the main bearing by a sealed welding method. The grease circulation channels inside the first mounting cylinder (201) and the second mounting cylinder (202) are connected to the raceway of the main bearing through axial through holes.

3. The monitoring device for the condition of lubricating grease in wind turbine main bearings according to claim 2, characterized in that: The drive mechanism (5) includes a servo motor (503), a sprocket (501) and a chain (502). The servo motor (503) drives the central shaft of the spiral blade (204) to rotate through the sprocket (501) and the chain (502).

4. The monitoring device for the condition of lubricating grease in wind turbine main bearings according to claim 3, characterized in that: The second mounting cylinder (202) has a mounting interface (205) at its end, which is adapted to the probe housing of the monitoring sensor (3) through a threaded sealing structure.

5. The monitoring device for the condition of lubricating grease in wind turbine main bearings according to claim 1, characterized in that: The monitoring end of the monitoring sensor (3) is connected to a rigid mounting sleeve (4), which passes through the second mounting cylinder (202) and the outside of the main bearing and extends into the raceway of the main bearing.

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