A gearbox oil filtration device with monitoring function

Abstract

This utility model relates to the field of wind power generation technology and discloses a gearbox oil filtration device with monitoring function, including a filter cartridge, and further including: an oil pump, which is fixedly connected to the outer wall of the filter cartridge and is used to transport gearbox oil into the filter cartridge; a filter screen, which is installed inside the filter cartridge; an oil monitor, one end of which is connected to the filter cartridge through a second oil inlet pipe and the other end of which is connected to the oil return pipe through a second oil outlet pipe, which is used to monitor the oil status inside the filter cartridge; and a pressure detection element, which is used to detect the pressure value between the inner wall of the filter cartridge and the outer wall of the filter screen. Through the synergy of continuous purification and real-time monitoring, this utility model can reduce the wear risk of gears and bearings at the source, realize intelligent early warning and status assessment during operation, and ultimately achieve the comprehensive benefits of "extending oil life, improving equipment reliability, and reducing operation and maintenance costs".

Description

Technical Field

[0001] This utility model relates to the field of wind power generation technology, specifically to a gearbox oil filtration device with monitoring function. Background Technology

[0002] Gearboxes, as key components in mechanical transmission systems, are widely used in wind power generation, rail transportation, construction machinery, ship propulsion, and industrial automation. Their operational reliability directly affects the stability and lifespan of the entire equipment system. During the long-term operation of a gearbox, lubricating oil not only lubricates, cools, and prevents rust, but also plays a crucial role in removing wear particles, contaminants, and oxidation products. However, with prolonged operation, metal shavings, dust, moisture, and gum and acidic substances produced by high-temperature oxidation inevitably mix into the oil. If these contaminants are not removed in time, they will accelerate the wear of critical components such as gears and bearings, and may even lead to serious failures such as pitting, galling, and fatigue fracture.

[0003] Traditional gearbox oil filtration equipment mainly uses mechanical filter elements to remove solid particulate impurities through physical interception. While this can maintain oil cleanliness to a certain extent, existing filtration devices usually lack the ability to online sense key indicators such as water content, viscosity changes, contamination levels, or metal particle concentration in the oil. This makes it difficult for maintenance personnel to accurately judge the trend of oil deterioration and the health status of the equipment. Traditional gearbox oil monitoring methods usually involve periodic sampling and testing or post-event maintenance, which is not only inefficient but also prone to missing the best maintenance opportunities. Utility Model Content

[0004] This invention provides a gearbox oil filtration device with monitoring function. By adding an independent filter cartridge outside the main oil circuit of the gearbox, continuous and fine purification of the oil is achieved, ensuring that ideal cleanliness is maintained under different operating conditions. In the filtration system, the oil monitor collects multi-dimensional data such as wear particles, viscosity, density, water content, dielectric constant, temperature, and contamination level in real time, realizing visualized monitoring of gearbox lubrication status and oil performance. This solves the problem mentioned in the background art of difficulty in accurately judging the trend of oil deterioration and the health status of equipment.

[0005] This utility model provides the following technical solution: A gearbox oil filtration device with monitoring function includes a filter cartridge, and further includes: an oil pump fixedly connected to the outer wall of the filter cartridge, the oil pump being used to deliver gearbox oil into the filter cartridge; a filter screen installed inside the filter cartridge for filtering the oil inside the filter cartridge, and a return oil pipe fixedly connected to the filter cartridge and communicating with the gearbox; an oil level monitor, one end of which is connected to the filter cartridge via a second oil inlet pipe, and the other end of which is connected to the return oil pipe via a second oil outlet pipe, the oil level monitor being used to monitor the state of the oil inside the filter cartridge; and a pressure detection element for detecting the pressure value between the inner wall of the filter cartridge and the outer wall of the filter screen.

[0006] As a preferred embodiment of the present invention, the filter cartridge has a base and an upper cylinder, the bottom of the upper cylinder is detachably connected to the base, and a first sealing gasket is installed at the connection between the upper cylinder and the base.

[0007] As a preferred embodiment of this utility model, the filter screen has a ring-shaped structure, and the top and bottom of the filter screen are fixedly connected with fixed rings, and the two fixed rings are fixedly connected by a support rod.

[0008] As a preferred technical solution of this utility model, a support platform is fixedly connected inside the base, the inner wall of the fixing ring at the bottom of the filter screen is threadedly connected to the outer wall of the support platform, and the top of the upper cylinder abuts against the top of the filter screen.

[0009] As a preferred embodiment of this utility model, a second sealing gasket is fitted on the support platform, and the bottom of the filter screen abuts against the second sealing gasket.

[0010] As a preferred technical solution of this utility model, a stepped limiting ring is fixedly connected to the top of the upper cylinder, a third sealing gasket is sleeved on the limiting ring, the top of the filter screen abuts against the third sealing gasket, and the outer wall of the small end of the limiting ring abuts against the inside of the filter screen.

[0011] As a preferred embodiment of this utility model, an oil outlet hole is provided on the support platform, and one end of the oil return pipe is connected to the oil outlet hole.

[0012] As a preferred embodiment of this utility model, a monitoring tube is fixedly connected to the top of the filter cartridge, the end of the second oil inlet pipe away from the oil monitor is connected to the monitoring tube, and a pressure sensor is fixedly connected to the monitoring tube.

[0013] As a preferred embodiment of this utility model, one end of the oil pump is connected to the gearbox through a first oil inlet pipe, and the other end of the oil pump is connected to the filter cartridge through a first oil outlet pipe.

[0014] As a preferred embodiment of this utility model, the pressure detection element includes a differential pressure switch installed on the filter cartridge, which is used to detect the pressure value between the inner wall of the filter cartridge and the outer wall of the filter screen.

[0015] Compared with the prior art, this utility model provides a gearbox oil filtration device with monitoring function, which has the following beneficial effects: 1. In this gearbox oil filtration device with monitoring function, an independent bypass circulation filter cartridge is added outside the main oil circuit of the gearbox to achieve continuous and fine purification of the oil, ensuring that ideal cleanliness can be maintained under different operating conditions. An oil monitor is installed in the filtration system to collect multi-dimensional data such as wear particles, viscosity, density, water content, dielectric constant, temperature and contamination level in real time, so as to realize the visual monitoring of gearbox lubrication status and oil performance.

[0016] The parts not covered in this device are the same as or can be implemented using existing technologies. Through the synergy of continuous purification and real-time monitoring, this project can reduce the wear risk of gears and bearings at the source, achieve intelligent early warning and status assessment during operation, and ultimately achieve the comprehensive benefits of "extending oil life, improving equipment reliability, and reducing operation and maintenance costs". Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, the elements or parts are not necessarily drawn to actual scale.

[0018] Figure 1 This is a first-person perspective perspective view of the present invention. Figure 2 This is a two-dimensional perspective view of the present invention. Figure 3 This is a cross-sectional view of the present invention; Figure 4 This utility model Figure 3 An enlarged schematic diagram of part A in the middle.

[0019] In the diagram: 1. Filter screen; 2. Filter cartridge; 201. Upper cylinder; 202. Base; 203. Support platform; 204. Oil return pipe; 205. Drain pipe; 206. Monitoring pipe; 207. Limiting ring; 3. Oil pump; 301. First oil inlet pipe; 302. First oil outlet pipe; 4. Oil level monitor; 401. Second oil inlet pipe; 402. Second oil outlet pipe; 5. Pressure sensor; 6. Differential pressure switch. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] Example: Reference Figures 1-4A gearbox oil filtration device with monitoring function includes a filter cartridge 2. The filter cartridge 2 has a base 202 and an upper cylinder 201. The bottom of the upper cylinder 201 is detachably connected to the base 202. The bottom of the upper cylinder 201 is connected by screws or latches, preferably screws. A first sealing gasket is installed at the connection between the upper cylinder 201 and the base 202 to improve the sealing effect between the upper cylinder 201 and the base 202 and reduce leakage. A drain pipe 205 with a valve is fixedly connected to the base 202 to facilitate the discharge of impurities from the filter cartridge 2 during subsequent cleaning. It also includes: an oil pump 3, which is fixedly connected to the outer wall of the filter cartridge 2. The oil pump 3 is used to transport gearbox oil into the filter cartridge 2. Specifically, one end of the oil pump 3 is connected to the inside of the gearbox through the first oil inlet pipe 301, and the other end of the oil pump 3 is connected to the inside of the filter cartridge 2 through the first oil outlet pipe 302. In use, by starting the oil pump 3, the oil in the gearbox can be drawn away and then transported into the filter cartridge 2, which has the functions of pressurization and oil delivery, improving the performance; and a filter screen 1, which is installed inside the filter cartridge 2 and is used to filter the oil inside the filter cartridge 2. The oil is filtered. Specifically, the filter screen 1 has a ring-shaped structure. Fixed rings are fixedly connected to the top and bottom of the filter screen 1, and the two fixed rings are fixedly connected by a support rod. Here, it is preferable to fix the filter screen 1 to the fixed rings with screws. In use, by fixing the fixed rings to the top and bottom of the filter screen 1 and fixing the support rod between the fixed rings, it is not only convenient to install the filter screen 1 during use, but also to improve the overall strength of the filter screen 1 and reduce the phenomenon of deformation of the filter screen 1. A return oil pipe 204, connected to the gearbox, is fixedly connected to the filter cartridge 2. The oil filtered by the filter cartridge 2 returns to the gearbox, effectively removing solid particulate impurities and maintaining oil cleanliness to a certain extent, thus improving the service life of gears, etc. An oil level monitor 4 is also included; one end of the monitor is connected to the filter cartridge 2 via a second inlet pipe 401, and the other end is connected to the return oil pipe 204 via a second outlet pipe 402. This means that the filtered filtrate, after being detected by the monitor, can return to the gearbox via the second outlet pipe 402. The oil flows into the return oil pipe 204 and then into the gearbox. One-way valves are installed on both the second oil pipe 402 and the return oil pipe 204 to prevent oil backflow. The oil monitor 4 is used to monitor the oil status in the filter cartridge 2. The oil monitor 4 is existing technology, and the preferred model is LWTD-1001. It integrates multiple detection probes for wear particles, kinematic viscosity, density, and trace moisture. It can also be equipped with dielectric constant and moisture content detection functions. It can detect ferromagnetic wear particles larger than 40μm and non-ferromagnetic wear particles larger than 150μm, and can statistically analyze wear particles in different size ranges.This equipment boasts excellent chemical corrosion resistance and pressure resistance, has no moving parts or consumables, and a design life of up to ten years. It transmits data via RS485 Modbus communication and is compatible with oil condition monitoring in heavy industrial equipment such as gearboxes. It possesses online sensing capabilities for key indicators such as water content, viscosity changes, contamination levels, or metal particle concentration in the oil, enabling maintenance personnel to accurately assess oil degradation trends and equipment health, thus improving maintenance efficiency. The pressure detection component measures the pressure between the inner wall of filter cartridge 2 and the outer wall of filter screen 1. This not only allows for real-time pressure monitoring within filter cartridge 2 but also enables timely detection of blockages in filter screen 1, improving overall performance.

[0022] A support platform 203 is fixedly connected inside the base 202. The inner wall of the fixing ring at the bottom of the filter screen 1 is threadedly connected to the outer wall of the support platform 203. Moreover, the top of the upper cylinder 201 abuts against the top of the filter screen 1, thereby fixing the filter screen 1 inside the filter cylinder 2 and enabling flexible assembly and disassembly, thus improving the performance.

[0023] In addition, a second sealing gasket is fitted on the support platform 203, and the bottom of the filter screen 1 abuts against the second sealing gasket, which can improve the sealing effect between the support platform 203 and the bottom of the filter screen 1. A stepped limiting ring 207 is fixedly connected to the top of the upper cylinder 201, and a third sealing gasket is fitted on the limiting ring 207. The top of the filter screen 1 abuts against the third sealing gasket, and the outer wall of the small end of the limiting ring 207 abuts against the inside of the filter screen 1. This not only improves the sealing effect between the filter screen 1 and the upper cylinder 201, but also reduces the radial displacement of the top of the filter screen 1, thus improving the performance.

[0024] An oil outlet is provided on the support platform 203, and one end of the return oil pipe 204 is connected to the oil outlet. That is to say, the oil entering the filter cylinder 2 passes through the filter screen 1, and the resulting filtrate can return to the gearbox through the oil outlet and the return oil pipe 204.

[0025] A monitoring tube 206 is fixedly connected to the top of the filter cartridge 2. The end of the second oil inlet pipe 401 away from the oil monitor 4 is connected to the monitoring tube 206. A pressure sensor 5, model PT131-G1 / 4-0-1MPa, is fixedly connected to the monitoring tube 206 to facilitate the detection of the pressure inside the filter screen 1.

[0026] The pressure detection device includes a differential pressure switch 6 installed on the filter cartridge 2. The differential pressure switch 6 is used to detect the pressure value between the inner wall of the filter cartridge 2 and the outer wall of the filter screen 1. The differential pressure switch 6 is existing technology. When the differential pressure reaches or exceeds the set value, the differential pressure switch 6 will automatically trigger its internal electrical contacts to operate (normally open becomes closed, or normally closed becomes open), thereby outputting a switch signal for alarm, interlock control, or starting / stopping related equipment, so as to realize the detection of the usage status of the filter screen 1.

[0027] This invention takes the operating conditions and maintenance needs of the main gearboxes of 24 units at the Dadingshan Wind Farm as an example. It aims to comprehensively improve the cleanliness management and status awareness capabilities of gearbox lubricating oil through an integrated solution of "adaptive dual filtration system + multi-parameter online oil monitoring." The overall approach focuses on oil cleanliness and lifespan extension as core objectives, using intelligent sensing and fine filtration as key technologies to build a replicable and scalable gearbox oil health management system.

[0028] In terms of implementation, firstly, an independent bypass circulation dual-filtration device is added outside the main oil circuit of the gearbox to achieve continuous and fine purification of the oil, ensuring that ideal cleanliness is maintained under different operating conditions. At the same time, an adaptive control strategy is used to dynamically adjust the filtration efficiency based on the real-time detected oil contamination level, which both extends the service life of the oil and reduces the burden on the main filter element. Secondly, a high-precision multi-parameter sensor module is integrated into the filtration system to collect multi-dimensional data such as wear particles, viscosity, density, water content, dielectric constant, temperature, and contamination level in real time, realizing visualized monitoring of the gearbox lubrication status and oil performance.

[0029] Through the synergy of continuous purification and real-time monitoring, this project can reduce the risk of wear on gears and bearings at the source, achieve intelligent early warning and status assessment during operation, and ultimately achieve comprehensive benefits such as "extending oil life, improving equipment reliability, and reducing operation and maintenance costs", providing a solid guarantee for the safe and efficient operation of the Dadingshan Wind Farm.

[0030] The wind farm is located in Shiqian County and Jiangkou County, Tongren City, Guizhou Province. Tongren City is situated on a slope transitioning from the Yunnan-Guizhou Plateau to the Xiangxi Hills, with higher elevations in the northwest and lower elevations in the southeast. The wind farm is approximately 52 km from Shiqian County and 70 km from Jiangkou County, covering a total area of ​​approximately 15.4 square kilometers, with a ground elevation ranging from 1300m to 1520m. The entire site is relatively remote. The Dadingshan Wind Farm has an installed capacity of 48MW, consisting of 24 Mingyang wind turbines, each with a capacity of 2.0MW. The main gearboxes are FD2250MG-01-00R2 manufactured by Nanjing High Speed ​​Gear Manufacturing Co., Ltd.

[0031] Specifically, during use, it improves oil filtration accuracy: the technical specifications specify the addition of a bypass fine filtration system, which directly increases the gear oil filtration accuracy from 10µm to 3µm, while simultaneously filtering out water and sludge that the main oil circuit filter cannot. This significantly improves gear oil cleanliness, extends oil lifespan, and most importantly, reduces wear on gear and bearing surfaces by filtering solid particles (metal shavings and grit), thus protecting gears and bearings. Furthermore, it provides early fault warning: through online oil monitoring technology, key parameters such as oil contamination, moisture, viscosity, and wear particles in the lubricating oil can be monitored in real time, promptly detecting early signs of lubricating oil performance degradation or mechanical component wear, providing early fault warnings for wind turbine gearboxes, and effectively preventing major failures. Based on online monitoring data, the health status of wind turbine gearboxes can be accurately assessed, allowing for the development of more scientific and reasonable maintenance plans, enabling a shift from scheduled maintenance to on-demand and predictive maintenance, reducing unnecessary downtime and maintenance costs. Timely and effective maintenance ensures that wind turbine gearboxes operate at their optimal condition, reducing downtime due to malfunctions and improving wind farm power generation and economic efficiency. Furthermore, it promotes intelligent management: online oil monitoring systems are a crucial component of intelligent wind farm management. Through integration with other monitoring systems, a comprehensive wind power equipment health management system can be built, enabling remote monitoring, intelligent analysis, and autonomous decision-making for wind farms. The implementation of wind turbine gearbox oil bypass filtration and online oil monitoring projects will promote technological innovation and application in areas such as reducing failure rates, fault diagnosis, and predictive maintenance within the wind power industry, driving the entire industry towards greater efficiency, intelligence, and sustainability.

[0032] Therefore, establishing an intelligent lubrication system with dual filtration and online monitoring in wind turbine gearboxes has significant research and application necessity. On the one hand, theoretically, there is a quantifiable physicochemical correlation between oil condition and equipment health. Multi-parameter monitoring models constructed based on fluid mechanics, tribology, and sensor principles (such as tuning fork resonance, humidity-sensitive capacitance, dielectric constant, and laser photoresist methods) can achieve joint assessment of lubricant degradation trends and equipment wear conditions. On the other hand, from an industry development perspective, wind power operation and maintenance is shifting from "post-event maintenance – periodic prevention" to "condition-based maintenance – predictive maintenance," and intelligent oil management technology has become a key direction for ensuring the long-term safe operation of wind turbine units.

[0033] Based on this, this project utilizes the 24 turbine units of the Dadingshan Wind Farm to construct an integrated solution of "adaptive dual-filtration system + multi-parameter online oil monitoring," achieving dynamic purification of oil contamination, real-time monitoring of performance degradation, and lifespan prediction. This technical approach has solid theoretical support and aligns with the industry's trend towards intelligent development. After implementation, it will not only significantly improve gearbox operational reliability and oil lifespan but also create a demonstration effect, providing a reference for the promotion of intelligent operation and maintenance in domestic wind farms. Specific technical parameters are as follows: (1) The dual filtration system should be connected in a bypass manner. The oil inlet of the dual filtration system is connected to the oil drain valve of the gearbox, and the oil outlet of the dual filtration system is connected to the main return oil pipe 204 of the lubrication system using a three-way connector. It is strictly forbidden to cause any situation that affects the pressure, lubrication and cooling of the original lubrication system. (2) The dual filtration system should be suitable for environments such as long-term mechanical vibration, dust, and high salt spray. The relevant sensors should have high-performance lightning protection and electronic compatibility to improve the system's environmental adaptability.

[0034] (3) Fine filtration should use a precision of 3μm or less (including 3μm).

[0035] (4) Filtration efficiency not less than β 4( c ) ≥1000, total dirt holding capacity 4kg, water absorption greater than 1.6L.

[0036] (5) The system flow rate is not less than 180L / h (when the oil temperature is 50°C) and the operating pressure is less than 3bar, so there is no risk of oil leakage.

[0037] (6) The filter housing meets C4L corrosion resistance standards. The housing is designed for a pressure of at least 12 bar.

[0038] (7) The dual filtration system should have online monitoring capabilities for the oil, including but not limited to online monitoring of the main gearbox oil contamination, moisture, viscosity, and wear particles, and the monitoring results should meet the requirements of the latest relevant standards. Among them, the cleanliness monitoring should adopt the light-shielding method and meet the requirements of ISO4406, and its accuracy should be ±0.5 cleanliness grades; the wear particle monitoring detection rate should be above 85% (including ferromagnetic and non-ferromagnetic particles); (8) The dual-filtration system should be capable of alarming and generating analysis reports based on the oil monitoring status. Its online sensor should be connected in series in the pipeline between the gearbox oil outlet and the circulating pump; (9) The software and hardware equipment related to the dual-filter system should meet the requirements of domestic production, including but not limited to servers, mainframes, chips, etc. At the same time, the full data can be connected to the centralized control center platform through SFTP, MQTT, etc.

[0039] Components not described in detail in this article are existing technologies.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A gearbox oil filtering device with monitoring function, comprising a filter cartridge (2), characterized in that, Also includes: Oil pump (3), the oil pump (3) is fixedly connected to the outer wall of filter cartridge (2), the oil pump (3) is used to transport gearbox oil into filter cartridge (2); A filter screen (1) is installed inside a filter cylinder (2) to filter the oil in the filter cylinder (2). A return oil pipe (204) connected to the gearbox is fixedly connected to the filter cylinder (2). Oil monitor (4), one end of the oil monitor (4) is connected to the filter cartridge (2) through the second oil inlet pipe (401), and the other end of the oil monitor (4) is connected to the return oil pipe (204) through the second oil outlet pipe (402). The oil monitor (4) is used to monitor the oil status in the filter cartridge (2). Pressure detection element, which is used to detect the pressure value between the inner wall of the filter cartridge (2) and the outer wall of the filter screen (1).

2. The gearbox oil filtration device with monitoring function according to claim 1, characterized in that, The filter cartridge (2) has a base (202) and an upper cylinder (201). The bottom of the upper cylinder (201) is detachably connected to the base (202), and a first sealing gasket is installed at the connection between the upper cylinder (201) and the base (202).

3. A gearbox oil filtration device with monitoring function according to claim 2, characterized in that, The filter screen (1) has a ring structure. The top and bottom of the filter screen (1) are fixedly connected with fixed rings, and the two fixed rings are fixedly connected by a support rod.

4. A gearbox oil filtration device with monitoring function according to claim 3, characterized in that, A support platform (203) is fixedly connected inside the base (202). The inner wall of the fixing ring at the bottom of the filter screen (1) is threadedly connected to the outer wall of the support platform (203), and the top of the upper cylinder (201) abuts against the top of the filter screen (1).

5. A gearbox oil filtration device with monitoring function according to claim 4, characterized in that, The support platform (203) is fitted with a second sealing gasket, and the bottom of the filter screen (1) abuts against the second sealing gasket.

6. A gearbox oil filtration device with monitoring function according to claim 4, characterized in that, The upper cylinder (201) is fixedly connected to a stepped limiting ring (207) at the top. A third sealing gasket is fitted on the limiting ring (207). The top of the filter screen (1) abuts against the third sealing gasket, and the outer wall of the small end of the limiting ring (207) abuts against the inside of the filter screen (1).

7. A gearbox oil filtration device with monitoring function according to claim 4, characterized in that, An oil outlet hole is provided on the support platform (203), and one end of the oil return pipe (204) is connected to the oil outlet hole.

8. A gearbox oil filtration device with monitoring function according to claim 1, characterized in that, The top of the filter cartridge (2) is fixedly connected to a monitoring tube (206), and the end of the second oil inlet pipe (401) away from the oil monitor (4) is connected to the monitoring tube (206), and a pressure sensor (5) is fixedly connected to the monitoring tube (206).

9. A gearbox oil filtration device with monitoring function according to claim 1, characterized in that, One end of the oil pump (3) is connected to the gearbox through the first oil inlet pipe (301), and the other end of the oil pump (3) is connected to the filter cartridge (2) through the first oil outlet pipe (302).

10. A gearbox oil filtration device with monitoring function according to claim 1, characterized in that, The pressure detection device includes a differential pressure switch (6) installed on the filter cartridge (2), which is used to detect the pressure value between the inner wall of the filter cartridge (2) and the outer wall of the filter screen (1).

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