Wind turbine yaw brake carbon dust collection device

Abstract

The application relates to the technical field of wind power generation, in particular to a yaw brake carbon powder collecting device of a wind turbine generator system. The carbon powder collecting device is connected with a nacelle of the wind turbine generator system, and the carbon powder collecting device comprises a dust collecting assembly and at least one cleaning assembly. The cleaning assembly comprises a brush roller and a first driving element, the first driving element is in transmission connection with the brush roller to drive the rotation of the brush roller, and the brush end of the brush roller is in contact with the friction surface of a yaw brake disc. The dust collecting assembly comprises a fan and a collecting box, the inside of the collecting box is provided with a collecting channel, one end of the collecting box is covered on the brush, the other end of the collecting box is connected with the fan, and the fan is configured to form negative pressure in the collecting channel. The design can effectively collect the carbon powder, prevent the carbon powder from floating again or accumulating, reduce the safety hidden trouble caused by the carbon powder accumulation to the operation of the unit, and guarantee the stable operation of the wind turbine generator system.

Description

Technical Field

[0001] This application relates to the field of wind power generation technology, and in particular to a carbon dust collection device for yaw brakes of wind turbine generator sets. Background Technology

[0002] During operation, the yaw system of a wind turbine needs to frequently operate to adjust the nacelle's orientation, ensuring the rotor is always facing the wind. This process relies on the friction between the yaw brake and the brake disc to achieve smooth braking and positioning.

[0003] However, during long-term operation, the friction between the brake pads and the brake disc generates a large amount of friction residue, namely carbon powder. This carbon powder easily adheres to the surface of the brake disc and between the brake pads, causing the following technical problems: Glaze layer formation: As carbon powder accumulates, under the action of braking pressure and frictional heat, when the temperature exceeds the thermal decay temperature of the brake pad, these residues will sinter on the surface of the brake pad, forming a hard and smooth "glaze layer".

[0004] Deterioration in braking performance: The presence of the enamel layer significantly alters the frictional characteristics between the friction pairs, leading to instability and fluctuations in the coefficient of friction. This not only reduces braking efficiency but may also induce vibration and noise during yaw.

[0005] Resonance risk: Fluctuations in the coefficient of friction may cause the vibration frequency generated by damping to couple with the unit's natural frequency, thus triggering resonance. Resonance can exacerbate uneven wear of brake pads, shorten their service life, and may damage other mechanical components of the yaw system.

[0006] Maintenance difficulties: Currently, the industry generally uses manual cleaning on a regular basis to remove carbon dust. This method is not only inefficient and labor-intensive, but also makes it difficult to thoroughly clean all areas of the brake disc (especially the complex dead corners), leading to recurring carbon dust accumulation problems.

[0007] Therefore, in view of the problems caused by the untimely and incomplete cleaning of carbon powder in the existing technology, there is an urgent need in the field for a device that can automatically and efficiently collect and remove carbon powder during the yaw process of wind turbine generators, so as to improve the stability and reliability of the yaw system and reduce maintenance costs. Summary of the Invention

[0008] In order to solve the above-mentioned technical problems, or at least partially solve the above-mentioned technical problems, this application provides a yaw brake carbon dust collection device for wind turbine generator sets.

[0009] This application provides a yaw brake toner collection device for a wind turbine generator set. The toner collection device is connected to the nacelle of the wind turbine generator set and includes a dust collection assembly and at least one cleaning assembly. The cleaning assembly includes a brush roller and a first driving member. The first driving member is kinetically connected to the brush roller to drive its rotation. The brush bristles of the brush roller contact the friction surface of the yaw brake disc. The dust collection assembly includes a fan and a collection box. The collection box has a collection channel inside. One end of the collection box covers the brush roller, and the other end is connected to the fan. The fan is configured to create a negative pressure in the collection channel.

[0010] In some embodiments, a dust collection box is also included, which is disposed at the end of the collection box away from the brush roller and communicates with the collection channel.

[0011] In some embodiments, the collection box includes a cover and a housing. The cover covers the brush roller, the housing forms the collection channel inside, and both ends of the housing are open. One end of the housing communicates with the interior of the cover, and the other end is provided with the fan.

[0012] In some embodiments, the first driving element is a motor, and the output shaft of the motor is connected to the brush roller.

[0013] In some embodiments, a fixed bracket is further included, which is used to connect the toner collection device to the nacelle of the wind turbine generator set; the fixed bracket is provided with a position adjustment structure, which is used to adjust the contact pressure between the brush roller and the friction surface of the yaw brake disc.

[0014] In some embodiments, the opening end of the housing is provided with a seal, which is in sealed contact with the friction surface of the yaw brake disc.

[0015] In some embodiments, a filter screen is provided at the connection between the dust collection box and the collection channel.

[0016] In some embodiments, the fan is configured with a second drive element, which is a motor independent of the first drive element; or, the first drive element is connected to both the fan and the brush roller via a transmission mechanism.

[0017] In some embodiments, the number of cleaning components is multiple, and the multiple cleaning components are arranged at circumferential intervals along the yaw brake disc.

[0018] In some embodiments, a control unit is further included, which is electrically connected to the first drive and / or the drive of the fan to control the start or stop of the cleaning assembly and the integrated assembly based on the yaw signal of the wind turbine.

[0019] The technical solution provided in this application has the following advantages compared with the prior art: The yaw brake carbon dust collection device for wind turbine generators provided in this application embodiment automatically cleans the carbon dust from the friction surface of the yaw brake disc by rotating a brush roller driven by a first driving component, eliminating the need for manual operation and significantly improving carbon dust cleaning efficiency compared to traditional manual cleaning methods. The wind turbine creates negative pressure within the collection channel, promptly drawing the carbon dust cleaned by the brush roller into the collection box. This design effectively collects carbon dust, preventing it from re-scattering or accumulating, reducing safety hazards caused by carbon dust buildup, and ensuring the stable operation of the wind turbine generator. The elimination of frequent manual carbon dust cleaning reduces the labor intensity of operators and minimizes their contact with carbon dust, reducing the risk of carbon dust inhalation and protecting their health. The device has a relatively simple structure, mainly composed of a brush roller, a first driving component, a wind turbine, and a collection box. The installation and connection methods of each component are conventional, facilitating daily maintenance and repair, and reducing maintenance costs. Attached Figure Description

[0020] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of the yaw brake carbon dust collection device of the wind turbine generator set described in the embodiments of this application.

[0023] The components include: 1. Yaw brake disc; 2. Brush roller; 3. First drive component; 4. Cover; 5. Housing; 6. Dust collection box; 7. Filter screen; and 8. Fan. Detailed Implementation

[0024] To better understand the above-mentioned objectives, features, and advantages of this application, the solution of this application will be further described below. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0025] Many specific details are set forth in the following description in order to provide a full understanding of this application, but this application may also be implemented in other ways different from those described herein; obviously, the embodiments in the specification are only some embodiments of this application, and not all embodiments.

[0026] like Figure 1 As shown in the embodiment of this application, a yaw brake toner collection device for a wind turbine generator set is provided. The toner collection device is connected to the nacelle of the wind turbine generator set. When the nacelle of the wind turbine generator set rotates, the toner collection device rotates together with the nacelle. The yaw brake disc 1 is fixed, that is, the toner collection device rotates relative to the yaw brake disc 1.

[0027] The yaw brake carbon dust collection device for a wind turbine generator set includes a dust collection assembly and at least one cleaning assembly. The cleaning assembly includes a brush roller 2 and a first drive member 3. The first drive member 3 is driven to rotate the brush roller 2. The brush bristles of the brush roller 2 contact the friction surface of the yaw brake disc 1. The dust collection assembly includes a fan 8 and a collection box. The collection box has a collection channel inside. One end of the collection box covers the brush, and the other end is connected to the fan 8. The fan 8 is configured to create a negative pressure in the collection channel.

[0028] The brush roller 2 uses a stainless steel roller frame with wear-resistant nylon bristles evenly planted on the outer layer. The bristle tips maintain a contact depth of 3-5mm with the friction surface of the yaw brake disc 1. One end of each brush roller 2 is connected to the first drive unit 3 via a coupling. The first drive unit 3 uses a 57BLDC brushless DC motor, and its output speed can be adjusted by a PLC controller (10-30r / min) to adapt to the toner cleaning needs under different working conditions.

[0029] In some embodiments of this application, the collection channel inside the collection box adopts a tapered design (inlet diameter 150mm, outlet diameter 80mm), and the inner wall of the channel is smoothed to reduce airflow resistance. The outlet end of the collection box is connected to the fan inlet through an 80mm diameter corrugated pipe. The fan is a 500W centrifugal fan, and its outlet extends through a pipe to the dust collection bag outside the cabin (which can be replaced periodically).

[0030] During operation, when the wind turbine performs a yaw action or detects that the amount of carbon dust accumulation has reached a threshold, the controller simultaneously starts the first drive unit 3 and the fan 8: During the rotation of the brush roller 2, the brush bristles sweep the carbon dust off the friction surface of the yaw brake disc 1; at the same time, the fan 8 forms a negative pressure of -300Pa to -500Pa in the collection channel, which draws the swept-off carbon dust into the collection channel and finally collects it into the dust collection bag.

[0031] The yaw brake carbon dust collection device for wind turbine generators provided in this embodiment automatically cleans the carbon dust on the friction surface of the yaw brake disc 1 by rotating the brush roller 2 driven by the first drive component 3, eliminating the need for manual operation and significantly improving carbon dust cleaning efficiency compared to traditional manual cleaning methods. A negative pressure is created within the collection channel, allowing the carbon dust cleaned by the brush roller 2 to be promptly sucked into the collection box. This design effectively collects carbon dust, preventing it from scattering or accumulating again, reducing safety hazards caused by carbon dust accumulation, and ensuring the stable operation of the wind turbine generator. The elimination of frequent manual carbon dust cleaning reduces the labor intensity of operators and minimizes their contact with carbon dust, reducing the risk of carbon dust inhalation and protecting their health. The device has a relatively simple structure, mainly composed of the brush roller 2, the first drive component 3, the fan 8, and the collection box. The installation and connection methods of each component are conventional, facilitating daily maintenance and repair, and reducing maintenance costs.

[0032] In some embodiments of this application, the yaw brake carbon dust collection device for wind turbine generators further includes a dust collection box 6, which is located at the end of the collection box away from the brush roller 2 and communicates with the collection channel. The dust collection box 6 is made of transparent polycarbonate (PC) material and has an overall rectangular structure (300mm long × 200mm wide × 250mm high). One side of the dust collection box has an interface (80mm in diameter) that matches the outlet end of the collection box. It is fixedly connected to the end of the collection box away from the brush roller 2 by a flange, so that the interior of the dust collection box 6 is completely connected to the collection channel. A filter assembly is detachably installed inside the dust collection box 6. This assembly includes two layers of filter screens 7: the outer layer is a metal mesh with a pore size of 50μm, used to intercept larger particulate impurities; the inner layer is a HEPA high-efficiency filter screen 7, which can filter carbon dust particles with a particle size of 0.3μm or larger, with a filtration efficiency of 99.7%.

[0033] On the other side of the dust collection box 6, there is an air outlet (70mm in diameter) connected to the fan 8. When the fan 8 is working, the negative pressure generated passes through the dust collection box 6 and the collection channel, acting on the area of ​​the brush roller 2. The top of the dust collection box 6 is equipped with an openable sealing cover, and the edge of the cover is fitted with a silicone sealing ring to ensure airtightness, making it convenient to periodically open and clean the collected toner or replace the filter components. In addition, the outer wall of the dust collection box 6 is also equipped with a transparent observation window with scale lines, which allows for direct observation of the amount of toner accumulated, making it easier for operators to determine when to clean.

[0034] During operation, the toner dust swept by the brush roller 2 first enters the collection channel under negative pressure, and is then sucked into the dust collection box 6. After being filtered by the filter assembly, the toner dust is trapped and deposited at the bottom of the dust collection box 6, while the clean air is discharged through the fan 8.

[0035] This embodiment achieves centralized storage and efficient filtration of toner by adding a dust collection box 6, avoiding equipment wear caused by toner directly entering the fan. At the same time, the transparent observation window design makes it easy to monitor the amount of toner collected, further improving the practicality and ease of maintenance of the device.

[0036] Furthermore, in some embodiments of this application, the collection box includes a cover 4 and a housing 5. The cover 4 covers the brush roller 2, the housing 5 forms a collection channel inside, and both ends of the housing 5 are open. One end of the housing 5 communicates with the interior of the cover 4, and the other end is provided with a fan 8.

[0037] The cover 4 is injection molded from high-strength ABS plastic, and has a semi-circular structure (the curvature matches the yaw brake disc 1). Its inner opening measures 300mm × 150mm, perfectly covering the outer side of the brush roller 2. The edge of the cover 4 is fitted to the side of the yaw brake disc 1 via a flexible rubber strip, forming a relatively enclosed cleaning space. The compression of the rubber strip can be controlled by adjusting bolts (typically maintaining a compression of 5-8mm) to ensure a tight seal while avoiding rigid contact with the yaw brake disc 1. The bottom of the cover 4 has a 120mm diameter connection port for communication with the housing 5.

[0038] The housing 5 is welded from a 2mm thick stainless steel plate, forming a cylindrical tubular structure (400mm in length and 120mm in inner diameter), with an internally continuous collection channel. One end of the housing 5 is sealed to the enclosure 4 via a flange (an oil-resistant rubber gasket is installed between the flanges), ensuring complete communication between the interior of the housing 5 and the enclosure 4. The other end of the housing 5 is also connected to the fan inlet via a flange structure, with a retractable corrugated pipe transition at the connection to absorb installation errors and equipment vibration.

[0039] The inner wall of housing 5 is polished (surface roughness Ra≤1.6μm) to reduce airflow resistance and toner adhesion. Near the enclosure 4, housing 5 is also equipped with a removable dust removal door (100mm×100mm). The dust removal door is secured by a snap-fit ​​structure, facilitating regular cleaning of toner that may have accumulated inside housing 5.

[0040] During operation, the toner generated by the brush roller 2 is first confined within the enclosed space formed by the cover 4. Under the negative pressure generated by the fan, the toner enters the collection channel of the housing 5 through the connection port of the cover 4, and is finally sucked into the fan 8 and transported to the subsequent collection device.

[0041] This embodiment clearly divides the collection shell into two parts: the cover 4 and the shell 5. This not only effectively seals the working area of ​​the brush roller 2, but also ensures the smooth flow of the toner conveying channel. At the same time, the metal shell 5 improves the durability of the device, and the design of the detachable dust removal door facilitates later maintenance.

[0042] Furthermore, in some embodiments of this application, the first driving component 3 is a motor, and the output shaft of the motor is connected to the brush roller 2.

[0043] In this embodiment, the first drive component 3 of the cleaning assembly adopts a DC brushless motor of model 60BLDC. The motor has a rated power of 150W and a rated speed of 300r / min. It can achieve stepless speed regulation from 0 to 300r / min through PWM signal to adapt to the cleaning needs of different carbon powder accumulation levels.

[0044] The motor is fixed to the steel structure at the bottom of the nacelle via an L-shaped metal bracket. Shock-absorbing rubber pads are installed at the connection between the bracket and the nacelle to reduce vibration transmission during motor operation. The motor's output shaft is directly driven to one end of the brush roller 2 via a key connection, with an axial positioning retaining ring installed at the connection to prevent detachment. The other end of the brush roller 2 is fixed to an auxiliary bracket via a deep groove ball bearing (model 6204), forming a two-end support structure to ensure stability during roller rotation.

[0045] To withstand harsh outdoor environments, the motor housing features an IP65 waterproof design with an anti-corrosion coating. The wiring terminals connect to the control system inside the cabin via waterproof aviation connectors. The control system can automatically start the motor based on yaw signals or timed programs. For example, when the unit detects a yaw angle exceeding 10°, it synchronously triggers the motor to perform toner cleaning.

[0046] During operation, the motor output shaft directly drives the brush roller 2 to rotate at a speed of 50-200 r / min (automatically adjusted according to the amount of toner). The friction generated by the contact between the bristles and the friction surface of the yaw brake disc 1 strips off the toner, which is then promptly sucked into the collection channel under negative pressure. Compared to indirect transmission methods, this direct connection structure reduces intermediate transmission components such as gears and belts, lowers mechanical losses and the risk of failure, while improving transmission efficiency and control precision.

[0047] This embodiment uses a DC brushless motor to directly drive the brush roller 2, which not only simplifies the transmission structure and improves reliability, but also achieves precise speed control. The cleaning intensity can be flexibly adjusted according to the actual working conditions, further optimizing the toner cleaning effect.

[0048] Furthermore, in some embodiments of this application, a fixed bracket is also included, which is used to connect the toner collection device to the nacelle of the wind turbine generator set; the fixed bracket is provided with a position adjustment structure, which is used to adjust the contact pressure between the friction surfaces of the brush roller 2 and the yaw brake disc 1.

[0049] The yaw brake carbon dust collection device of the wind turbine generator set in this embodiment includes a fixed bracket connected to the nacelle. The bracket is welded from Q235 steel plate and the main body is a "door" shaped frame structure (400mm × 600mm wide). The bottom is fixed to the steel structure beam at the bottom of the nacelle by expansion bolts.

[0050] The crossbeam of the fixed bracket is equipped with a position adjustment structure, which consists of an adjusting screw, a sliding seat, and a locking nut. The sliding seat is fitted on the crossbeam (with a clearance of 0.5mm) and can slide horizontally along the crossbeam. One end of the adjusting screw is connected to the sliding seat through a hinge support, and the other end passes through the vertical beam of the bracket and is equipped with double locking nuts (M16 specification). The bearing seat of the brush roller 2 and the first driving component 3 are both fixed on the sliding seat, forming an integral adjustable unit.

[0051] During adjustment, loosen the locking nut and rotate the adjusting screw to push the sliding seat, which in turn moves the brush roller 2 horizontally (adjustment range ±20mm). The contact pressure (measured pressure range 5-30N) is controlled by changing the contact depth between the brush bristles and the friction surface of the yaw brake disc 1 (adjustable from 2-8mm). After adjustment, tighten the double nuts to achieve mechanical locking, with a positioning accuracy of ±0.5mm.

[0052] In addition, the contact surface between the sliding seat and the crossbeam is provided with scale lines (minimum division 1mm), which, together with the pointer on the bracket, allows for intuitive reading of the adjustment amount; the end of the adjusting screw is equipped with a rotating handwheel (80mm in diameter) for easy manual operation, and the edge of the handwheel is provided with anti-slip texture.

[0053] The advantages of this design are: the contact pressure can be adjusted periodically according to the degree of brush bristle wear, ensuring stable cleaning performance over a long period; it can adapt to the thickness differences of different models of yaw brake discs 1 (the adjustment range covers the thickness deviation of conventional yaw brake discs 1); during maintenance, the brush roller 2 can be moved away from the yaw brake disc 1 through the adjustment structure, facilitating maintenance operations. In practical applications, the contact pressure is usually set to 15-20N during new installation, and when the brush bristles wear down to 2mm, the adjustment structure compensates to maintain optimal cleaning force.

[0054] In some embodiments of this application, the opening end of the cover is provided with a seal, which is sealed and fitted to the friction surface of the yaw brake disc 1.

[0055] In this embodiment, a sealing element is provided on the edge of the opening end of the cover 4 (the side opposite to the yaw brake disc 1). The sealing element is made of silicone rubber with a Shore hardness of 60° and has an "L" shaped cross section (20mm wide on the horizontal side and 15mm high on the vertical side). It is fixedly connected to the edge of the cover 4 by high-strength adhesive.

[0056] The inner side of the seal's horizontal edge fits against the cover 4, while the vertical edge extends towards the yaw brake disc 1. Its end is machined into a rounded lip structure (3mm radius), which can generate uniform deformation pressure when in contact with the friction surface of the yaw brake disc 1. To enhance durability, a 0.2mm thick stainless steel reinforcing sheet is embedded in the lip contact part of the seal, ensuring both elastic contact and preventing excessive wear.

[0057] During installation, the position adjustment structure maintains a compression of 0.5-1mm between the seal and the friction surface of the yaw brake disc 1, forming a reliable seal while avoiding excessive resistance. The overall length of the seal matches the edge of the opening of the cover 4, and the corners are made using an integrated molding process to eliminate splicing gaps, ensuring complete coverage of the gap between the cover 4 and the yaw brake disc 1.

[0058] In addition, the surface of the seal is coated with polytetrafluoroethylene, with a friction coefficient of ≤0.15, which can reduce wear when moving relative to the yaw brake disc 1; on the side near the brush roller 2, the seal is also provided with annular ribs (2mm high) to further enhance the blocking effect on carbon powder.

[0059] The advantages of this design are: the gap between the cover 4 and the yaw brake disc 1 is eliminated by the elastic seal, so that the negative pressure can be applied to the cleaning area more effectively, and the carbon powder collection efficiency is increased to more than 95%; the lip structure can adapt to the slight sway of the yaw brake disc 1, ensuring long-term sealing effect; the low friction coefficient design reduces the impact on the normal operation of the yaw brake disc 1, while extending the service life of the seal (the actual service life can reach more than 12 months).

[0060] Furthermore, in some embodiments of this application, a filter 7 is provided at the connection between the dust collection box 6 and the collection channel.

[0061] The filter screen adopts a double-layer composite structure, and the whole is fixed to the inlet flange of the dust collection box 6 (connected to the outlet of the collection channel) by a snap-on frame. The outer layer is a coarse filter screen 7, which is made of 304 stainless steel woven mesh with a mesh diameter of 0.5mm and a thickness of 1mm. It is mainly used to intercept larger particles of impurities (such as metal shavings, brake pad wear particles, etc.) that may be mixed in during the cleaning process, preventing them from entering the dust collection box 6 and causing blockage.

[0062] The inner layer is a fine filter 7, made of PTFE (polytetrafluoroethylene) membrane filter media, with a rated filtration accuracy of 10μm and a filtration efficiency of over 99% for carbon powder. The fine filter 7 features a wavy pleated design, which can increase the filtration area by 3 times in the same installation space (the unfolded area reaches 0.15㎡), effectively reducing airflow resistance (initial resistance ≤80Pa).

[0063] The frame of filter 7 is injection molded from ABS engineering plastic, and a nitrile rubber sealing ring is provided between it and the sealing surface of the dust collection box 6 inlet to ensure that all airflow is filtered by filter 7. A handle is provided on one side of the frame for easy removal, and filter 7 can be quickly disassembled and replaced. The replacement cycle is set to 3-6 months depending on the amount of toner produced.

[0064] In addition, a pressure sensor is installed downstream of the filter assembly (near the inside of the dust collection box 6). When too much carbon powder adheres to the surface of the filter 7, causing the resistance to exceed 300Pa, the sensor will send a signal to the cabin control system to remind maintenance personnel to replace the filter 7 in time.

[0065] The advantages of this design are: the dual-layer filter structure achieves graded filtration, which can intercept large particles of impurities to protect the equipment, while efficiently capturing fine carbon dust; the wave-shaped design extends the service life of filter 7 and reduces energy consumption; the convenient replacement structure and intelligent reminder function greatly improve maintenance convenience. In actual operation, this filter 7 can reduce the dust content of the air entering the fan to below 0.01mg / m³, effectively avoiding wear on the fan impeller and secondary diffusion of carbon dust.

[0066] In some embodiments of this application, the fan 8 is equipped with a second driving member, which is a motor independent of the first driving member 3; or, the first driving member 3 drives the fan 8 and the brush roller 2 simultaneously through a transmission mechanism.

[0067] In this embodiment, the wind turbine drive method of the yaw brake carbon dust collection device of the wind turbine generator set can adopt the following two schemes: Option 1: Independent drive method The fan is equipped with an independent second drive unit, which uses a DC brushless motor (different from the first drive unit 3), with a rated power of 200W, a rated speed of 2800r / min, and an IP66 protection rating. The motor is directly connected to the impeller shaft of the centrifugal fan via a flange, forming an integrated structure, and is installed at the air outlet end of the dust collection box 6.

[0068] The second drive unit and the first drive unit 3 (the drive motor of the brush roller 2) are powered independently and controlled separately by the PLC controller in the machine compartment. The fan speed can be flexibly adjusted (adjustable from 1000-2800 r / min) according to the toner cleaning requirements, so as to achieve precise control of the negative pressure intensity. For example, when the brush roller 2 is cleaning at high speed (200 r / min), the fan runs synchronously at high speed (2800 r / min) to generate strong negative pressure; while in the daily inspection mode, the fan can be started alone to run at low speed (1000 r / min) for light dust suction.

[0069] Option 2: Linkage-driven approach The first drive unit 3 (60BLDC motor, 300W) simultaneously drives the brush roller 2 and the fan through a transmission mechanism. The transmission mechanism consists of a drive gear, a transition gear, and a synchronous pulley: the motor output shaft is connected to the drive gear (module 2, 18 teeth), the drive gear meshes with the transition gear (module 2, 36 teeth), and the transition gear is coaxially fixed with a 50mm diameter drive synchronous pulley; one end of the brush roller 2 is provided with a 100mm diameter driven synchronous pulley, which is connected to the drive synchronous pulley through a polyurethane synchronous belt (transmission ratio 2:1); at the same time, the transition gear meshes with the driven gear (module 2, 24 teeth) at the end of the fan shaft (transmission ratio 3:2).

[0070] This linkage structure establishes a fixed rotational speed relationship between the brush roller 2 and the fan: when the motor output speed is 300 r / min, the brush roller 2 rotates at 150 r / min, and the fan speed is 2000 r / min, ensuring that the sweeping volume matches the suction volume. The transmission mechanism housing is sealed with aluminum alloy material and filled with lithium-based grease, making it suitable for outdoor high and low temperature environments (-30℃ to +60℃).

[0071] Advantages of the two solutions: Solution 1's independent drive allows for asynchronous operation of the brush and fan, resulting in better energy efficiency; Solution 2's linked drive reduces the number of motors, lowering equipment costs and installation space requirements, making it suitable for space-constrained nacelle environments. In practical applications, the choice can be made flexibly based on the unit model and operating conditions.

[0072] Furthermore, in some embodiments of this application, there are multiple cleaning components, which are spaced apart circumferentially along the yaw brake disc 1.

[0073] For example, in an embodiment of this application, there are four cleaning components, evenly spaced along the circumference of the yaw brake disc 1 (adjacent components are at an angle of 90°), forming a full-range coverage of the friction surface of the yaw brake disc 1. Each brush roller 2 is covered with an independent arc-shaped cover 4, and the open end of the cover 4 is fitted to the yaw brake disc 1 through a silicone rubber seal; the bottom outlets of the four covers 4 are connected to the collection channel through a four-way pipe, and the end of the collection channel is connected in sequence to the dust collection box 6 (with a filter 7) and the fan 8.

[0074] During operation, the four brush rollers 2 start rotating synchronously to clean the friction surface of the yaw brake disc 1 from different directions; the negative pressure generated by the fan is distributed to each hood 4 through the main channel, and the carbon powder cleaned in each area is simultaneously sucked into the dust collection box 6.

[0075] Furthermore, in some embodiments of this application, the wind turbine yaw brake carbon dust collection device further includes a control unit, which is electrically connected to the drive unit of the first drive unit 3 and / or the drive unit of the fan 8, to control the start or stop of the cleaning assembly and the dust collection assembly according to the yaw signal of the wind turbine.

[0076] The yaw brake carbon dust collection device of the wind turbine generator set in this embodiment includes a control unit. The control unit uses a microcontroller as the core controller and is installed in the electrical control cabinet inside the nacelle. It is electrically connected to the first drive component 3 (the motor connected to the brush roller 2) and the wind turbine drive component (the second drive component) through shielded cables.

[0077] The control unit's signal input is connected to the yaw control system of the wind turbine generator set, allowing it to receive yaw signals from the generator set in real time, including yaw start signal, yaw direction signal (clockwise / counterclockwise), yaw angle signal, and yaw speed signal. The control unit has pre-set control logic: upon receiving the yaw start signal, it synchronously starts the first drive component 3 and the wind turbine drive component after a 2-second delay; after the yaw signal stops, it continues to run for 30 seconds before shutting down, ensuring that residual toner is thoroughly cleaned and collected.

[0078] The control unit is equipped with an LCD display and buttons, allowing on-site parameter settings such as: yaw angle threshold (default 5°, cleaning is triggered when the yaw angle exceeds this value), cleaning duration (adjustable from 10-60 seconds), brush roller speed (50-200 r / min), and fan airflow level (3 adjustable levels). Simultaneously, the control unit also has communication capabilities, connecting to the unit's system via an interface to upload equipment operating status (such as motor current, running time, fault codes, etc.) and receive remote control commands.

[0079] To improve reliability, the control unit is equipped with multiple protection mechanisms: when the motor current is detected to exceed 150% of the rated value, it will automatically shut down and issue an overload alarm; when the fan inlet pressure is abnormal (below -600Pa or above -100Pa), it is determined that the filter 7 is blocked or the pipeline is leaking, and a maintenance reminder will be issued; it has undervoltage and overvoltage protection functions and can adapt to fluctuations in the 110V DC power supply in the nacelle (allowing ±20% deviation).

[0080] The actual workflow is as follows: When the wind turbine needs to yaw to face the wind, the yaw control system sends a yaw start signal and a direction signal to the control unit; the control unit starts the brush roller 2 and the wind turbine according to the preset logic, and the brush roller 2 rotates in the opposite direction to the yaw direction (to improve cleaning efficiency); after the yaw is completed, the control unit delays shutting down the equipment and uploads information such as the cleaning time and motor operating parameters to the system.

[0081] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0082] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments described herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A yaw brake carbon dust collection device for wind turbine generator sets, characterized in that, The toner collection device is connected to the nacelle of the wind turbine generator set, and the toner collection device includes a dust collection component and at least one cleaning component. The cleaning component includes a brush roller (2) and a first drive member (3). The first drive member (3) is driven to the brush roller (2) to drive it to rotate. The brush ends of the brush roller (2) are in contact with the friction surface of the yaw brake disc (1). The dust collection component includes a fan (8) and a collection box. The collection box has a collection channel inside. One end of the collection box is covered on the brush, and the other end is connected to the fan (8). The fan (8) is configured to form a negative pressure in the collection channel.

2. The wind turbine yaw brake carbon dust collection device according to claim 1, characterized in that, It also includes a dust collection box (6), which is located at the end of the collection box away from the brush roller (2) and is connected to the collection channel.

3. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, The collection box includes a cover (4) and a housing (5). The cover (4) covers the brush roller (2). The collection channel is formed inside the housing (5). Both ends of the housing (5) are open. One end of the housing (5) is connected to the inside of the cover (4), and the other end is provided with the fan (8).

4. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, The first driving component (3) is a motor, and the output shaft of the motor is connected to the brush roller (2).

5. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, It also includes a fixed bracket for connecting the toner collection device to the nacelle of the wind turbine generator set; the fixed bracket is provided with a position adjustment structure for adjusting the contact pressure between the friction surfaces of the brush roller (2) and the yaw brake disc (1).

6. The wind turbine generator yaw brake carbon dust collection device according to claim 3, characterized in that, The opening end of the cover (4) is provided with a sealing element, which is sealed and fitted to the friction surface of the yaw brake disc (1).

7. The wind turbine generator yaw brake carbon dust collection device according to claim 2, characterized in that, A filter screen (7) is provided at the connection between the dust collection box (6) and the collection channel.

8. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, The fan (8) is equipped with a second drive unit, which is a motor independent of the first drive unit (3); or, the first drive unit (3) is connected to the fan (8) and the brush roller (2) simultaneously through a transmission mechanism.

9. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, The number of cleaning components is multiple, and the multiple cleaning components are arranged at intervals along the circumference of the yaw brake disc (1).

10. The wind turbine generator yaw brake carbon dust collection device according to claim 1, characterized in that, It also includes a control unit electrically connected to the first drive (3) and / or the drive of the fan (8) to control the start or stop of the cleaning assembly and the dust collection assembly according to the yaw signal of the wind turbine.

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