Testing device and testing procedure for testing a rotary bearing

Abstract

The application relates to a test device (100) for testing a rotary bearing (200), in particular a main bearing comprising at least one rolling bearing for a wind turbine, under a load, wherein the rotary bearing (200) comprises a first rotary bearing component (210) and a second rotary bearing component (220) rotatable about an axis of rotation (110) relative to the first rotary bearing component (210), wherein the test device (100) comprises: a transmission bearing (300) with a first transmission bearing component (310) and a second transmission bearing component (320) rotatable about the axis of rotation (110) relative to the first transmission bearing component (310), a stationary holding block (400), in particular a reaction block of a rotor blade test stand, which is rigidly connectable or connected to the first rotary bearing component (210) or the first transmission bearing component (310),and a load transfer device (500) for applying the load to the rotary bearing (200), wherein the load transfer device (500) is rigidly connectable or connected to that component from the group consisting of the first rotary bearing component (210) and the first transfer bearing component (310) which is not rigidly connected to the retaining block (400), and the second transfer bearing component (320) is rigidly connectable or connected to the second rotary bearing component (220). The application further relates to a corresponding test method.

Description

[0001] The application relates to a test device for testing a rotary bearing under load and a corresponding test procedure. The device is particularly advantageous for testing a main bearing for a wind turbine, especially a main bearing comprising at least one rolling bearing.

[0002] Testing large slewing bearings, such as those used in wind turbines with diameters of several meters, requires the application of significant forces and moments. One known test rig involves placing the slewing bearing under test in a load frame. This frame transmits forces and moments generated by hydraulic cylinders to the slewing bearing, while a component of the bearing can be rotated by means of an axially arranged drive train. Providing and operating such a setup can involve considerable engineering and financial investment.

[0003] In light of the state of the art, the application aims to provide a testing device and a testing procedure that enable the simplest and most cost-effective testing of rotary bearings, in particular large rolling bearings of the type mentioned.

[0004] To solve the problem, a testing device and a testing method are proposed according to the respective independent claims. Advantageous embodiments and further developments result in conjunction with the features of the dependent claims.

[0005] The disclosed test device is designed for testing a rotary bearing under load, wherein the rotary bearing comprises a first rotary bearing component and a second rotary bearing component rotatable about an axis of rotation relative to the first rotary bearing component. The rotary bearing can be a main bearing for a wind turbine, in particular a main bearing for a wind turbine comprising at least one rolling bearing. Other rotary bearings, including large plain bearings, can also be tested using the test device.

[0006] The test device includes: a transmission bearing with a first transmission bearing component and a second transmission bearing component rotatable around the axis of rotation relative to the first transmission bearing component, a stationary holding block, in particular a reaction block of a rotor blade test stand, which is rigidly connectable or connected to the first rotary bearing component or the first transmission bearing component, and a load transfer device for applying the load to the rotary bearing.

[0007] It is provided that the load transfer device is rigidly connectable or connected to that component from the group consisting of the first slewing bearing component and the first transfer bearing component which is not rigidly connected to the holding block, and that the second transfer bearing component is rigidly connectable or connected to the second slewing bearing component.

[0008] In the disclosed test device, the rotary bearing under test is coupled on the one hand to a static structure (namely the holding block) and on the other hand to the load transmission device in such a way that the latter is arranged, or can be arranged, in particular in an axial extension of the rotary bearing's axis of rotation. The transmission bearing enables this coupling, by means of which the rotary bearing can be rotated under load for testing purposes.

[0009] This design enables testing in a comparatively simple and cost-effective manner. In particular, an existing testing device designed for other purposes, such as a test stand for wind turbine rotor blades, can be used as the testing apparatus.

[0010] The holding block can therefore be a reaction block of a test rig for load tests of large components (with, for example, a length on the order of 10 m to 100 m), in particular a rotor blade test rig.

[0011] The holding block can be designed to absorb large static and / or dynamic bending moments, such as those that occur during the load testing of rotor blades. Moments required for testing main bearings, for example, ranging from approximately 10 MNm to 120 MNm, can thus be absorbed. The holding block preferably also has a mounting surface arranged perpendicular or nearly perpendicular to the ground for rigid connection to a test specimen or corresponding adapter. A reinforced foundation can be provided in the ground in the area of ​​the holding block, particularly in front of the holding block in the area of ​​the load to be bolted on. A reaction block of a rotor blade test rig typically fulfills the aforementioned requirements.

[0012] The load transfer device can include a lever arm. This allows high moments to be exerted on the slewing bearing, particularly by utilizing the length of the lever arm. The lever arm can have a length of approximately 10 m to 100 m. The lever arm can, in particular, comprise a rotor blade or at least one tower segment for a wind turbine. Rotor blades typically have lengths of 20 m to 80 m. A lever arm of suitable length can also be formed from one or more tower segments. Due to the mass and length of the lever arm, the load transfer device can intrinsically generate a static base load on the slewing bearing. To increase the static base load, the test setup can include at least one axially aligned load cylinder.The at least one load cylinder can be rigidly connected or connectable to the load transfer device and / or the component rigidly connected to it from the group consisting of the first rotary bearing component and the first transfer bearing component.

[0013] The lever arm can be a component that was previously used in a wind turbine and / or is defective and / or has been tested using the rotor blade test rig. Using such a previously used and / or unusable lever arm can make testing the rotary bearing particularly cost-effective.

[0014] The test device can be configured for the simultaneous testing of the aforementioned (first) rotary bearing and a further (second) rotary bearing. For this purpose, a component of the second rotary bearing can be rigidly connected to a component, in particular the second rotary bearing component, of the first rotary bearing. The second rotary bearing can be identical in construction to the first rotary bearing or different from it. The first and second rotary bearings can be arranged for simultaneous testing in a back-to-back configuration (i.e., in an arrangement inverted relative to each other along the axis of rotation, in particular with the non-rotating bearing component facing outwards). It can be provided, in particular, that the further rotary bearing is used as a transfer bearing in the sense described above. In this way, a particularly simple and cost-effective testing of two rotary bearings can be achieved.

[0015] The test device can further include a drive device for applying a torque to the second slewing bearing component, which is rigidly connected to the second transmission bearing component, such that the second slewing bearing component can be set into rotation during the application of the load to the slewing bearing. In this way, the slewing bearing can be tested under the most realistic operating conditions possible.

[0016] The drive device can, in particular, engage a bearing adapter connecting the second rotary bearing component to the second transmission bearing component. In this way, an axial arrangement of the drive device with respect to the axis of rotation of the rotary bearing is not required, so that the rotary bearing can be arranged axially between the retaining block and the load transmission device. The drive device can include a gear, a drive belt, or another transmission element for transmitting the torque. The drive device can include a motor, in particular an electric motor.

[0017] The test device may further include a load application device for applying a force and / or moment to the load transmission device, in particular the lever arm, to generate the load. The required forces or moments can be applied statically and / or dynamically by means of the load application device. The load application device may, in particular, include at least one hydraulic cylinder and / or at least one winch for generating the force or moment and / or at least one rope, at least one chain and / or at least one transmission rod for transmitting the force or moment to the load transmission device.

[0018] The load application device may include at least one load frame designed to apply a bending moment to the lever arm.

[0019] The load frame can be, in particular, a load frame used in rotor blade testing on a rotor blade test stand. The load frame can have an internal profile for positively engaging a rotor blade or tower segment used as a lever arm. The load frame can be coupled to, or be capable of being coupled to, the hydraulic cylinder(s) and / or the winch(es) of the load application device. By using a load frame, especially one originally designed for testing a rotor blade used as a lever arm, the required load can be applied in a particularly simple and cost-effective manner.

[0020] The load application device may include a locking device for maintaining the static load. This locking device may consist of, for example, lockable winches and / or a device for mechanically clamping hydraulic cylinders and / or associated ropes, chains, and / or transmission rods. A locking device can, for instance, reduce the energy expenditure required to maintain or readjust the static load (e.g., for re-pumping a hydraulic circuit for the hydraulic cylinders or for re-tensioning the winches) and the associated costs.

[0021] The test fixture can include a rotationally fixed suspension and / or support for the load transfer device. This secures the load transfer device and the rigidly connected component from the group consisting of the first rotary bearing component and the first transfer bearing component against rotation about the axis of rotation, particularly with respect to the mounting block and / or a substrate, in a rotationally fixed manner. For example, the lever arm and / or the aforementioned component can be clamped in such a way that it / they cannot rotate about the axis of rotation.

[0022] The rotationally fixed suspension and / or support can comprise two crosswise hydraulically connectable or linked double-chamber hydraulic cylinders, which may in particular be hydraulic cylinders of the load application device. Crosswise means that, for example, when the two double-chamber hydraulic cylinders are arranged in parallel, each chamber of the first cylinder is hydraulically connectable or linked to the opposite chamber of the second cylinder. In such an arrangement, the pistons of both cylinders can move in the same direction but not in opposite directions, thus enabling a rotationally fixed load application.

[0023] The test device can include at least one bearing adapter for rigidly connecting the first rotary bearing component or the first transmission bearing component to the mounting block and / or for rigidly connecting the first transmission bearing component or the first rotary bearing component to the load transfer device and / or for rigidly connecting the second rotary bearing component to the second transmission bearing component. Preferably, the test device includes one of each of the three aforementioned bearing adapters. The bearing adapter(s) can be screwed and / or flanged to the respective components and / or rigidly coupled in some other way. The bearing adapter(s) can be adapter rings.

[0024] The test device may include a sensor array for acquiring measured values ​​that correspond to parameters of the rotary bearing under load and / or provide information about such parameters. The sensor array may be configured, for example, to detect loads, such as by means of load cells and / or by evaluating hydraulic parameters of hydraulic cylinders. The sensor array may be configured to detect vibrations and / or deformations and / or temperatures. The sensor array may be configured to detect torques, for example, based on the drive currents required to operate the drive device.

[0025] The disclosed test method is intended for testing a rotary bearing, in particular a main bearing comprising at least one rolling bearing for a wind turbine, under a load, wherein the rotary bearing comprises a first rotary bearing component and a second rotary bearing component rotatable about an axis of rotation relative to the first rotary bearing component.

[0026] The testing procedure includes the following steps: rigid connection of the second rotary bearing component with a second transmission bearing component of a transmission bearing, which is rotatable about the axis of rotation relative to a first transmission bearing component of the transmission bearing, rigid connection of the first rotary bearing component or the first transmission bearing component to a stationary holding block, in particular a reaction block of a rotor blade test stand, rigid connection of that component from the group consisting of the first slewing bearing component and the first transmission bearing component which is not rigidly connected to the holding block, to a load transmission device which in particular comprises a rotor blade or at least one tower segment for a wind turbine, and Applying the load to the rotary bearing using the load transfer device.

[0027] The test procedure can be carried out, in particular, using the disclosed test device. Accordingly, the test procedure can be further developed with process steps corresponding to optional features of the test device.

[0028] Examples of the subject matter of the application are explained below with reference to drawings. These show, in each case schematically and in a simplified manner, Fig. 1 a side view of a test device, Fig. 2 a longitudinal section of a part of the test device according to Fig. 1.

[0029] Recurring and similar features are identified in the drawings with identical alphanumeric reference symbols. Reference symbols already shown in other drawings may be partially omitted.

[0030] The in Fig. 1 and in part in Fig. The test device 100 shown is intended for testing a rotary bearing 200 under a load, in particular within the framework of a test procedure described at the same time as the test device.

[0031] The rotary bearing 200 comprises a first rotary bearing component 210 and a second rotary bearing component 220 rotatable about a rotation axis 110 relative to the first rotary bearing component 210. In the example shown, the rotary bearing 200 is a main bearing for a wind turbine, designed as a double-row tapered roller bearing in an O-arrangement (torque bearing) with tapered rollers 230 arranged between the first and second rotary bearing components. Other bearing geometries and other rotary bearing types, including split rolling bearings with two preloaded tapered roller bearings or large rotary plain bearings, can also be tested using the test device 100.

[0032] The test device 100 comprises a transmission bearing 300 with a first transmission bearing component 310 and a second transmission bearing component 320 rotatable relative to the first transmission bearing component 310 about the axis of rotation 110.

[0033] The test device 100 is based on a test stand for rotor blades of wind turbines (rotor blade test stand) and includes the reaction block of the rotor blade test stand as a stationary holding block 400, which can be rigidly connected to the first rotary bearing component 210 by means of a first bearing adapter 610.

[0034] The retaining block 400 is designed to absorb static and / or dynamic bending moments sufficient for testing the rotary bearing 200, for example, in the range of 10 MNm to 120 MNm. The retaining block 400 has a mounting surface 410 arranged perpendicular or nearly perpendicular to the ground, which can be connected to the first bearing adapter 610 by screwing it on. A reinforced foundation is provided in the ground in the area of ​​the retaining block 400.

[0035] The test device 100 comprises a load transfer device 500 for applying the load to the rotary bearing 200. The load transfer device 500 can be rigidly connected to the first transfer bearing component 310 by means of a second bearing adapter 620, so that the load transfer device 500 can be arranged in an axial extension of the rotation axis 110 of the rotary bearing 200. The second transfer bearing component 320 can be rigidly connected to the second rotary bearing component 220 by means of a third bearing adapter 630. The transfer bearing 300 thus enables a coupling by means of which the rotary bearing 200 can be operated rotatably under load for testing. The bearing adapters 610, 620, and 630 are designed as adapter rings.

[0036] The test procedure includes a rigid connection of the second rotary bearing component 220 to the second transmission bearing component 320 by means of the third bearing adapter 630, a rigid connection of the first rotary bearing component 220 to the retaining block 400 by means of the first bearing adapter 610, and a rigid connection of the first transmission bearing component 320 to the load transfer device 500 by means of the second bearing adapter 620.

[0037] In the arrangement and corresponding process steps described so far, the roles of the rotary bearing 200 and the transmission bearing 300 can alternatively be interchanged. Likewise, the roles of the respective first components 210, 310 (here: outer / fixed bearing component) and the respective second components 220, 320 (here: inner / rotating bearing component) can be interchanged. Instead of using bearing adapters 610, 620, 630, the connection of the elements or individual elements can be carried out directly, for example by screwing them on, flanges, etc.

[0038] The load transfer device 500 comprises a rotor blade with a length in the range of 20 m to 80 m as a lever arm 510. The lever arm 510 can alternatively be configured differently, for example comprising at least one tower segment for a wind turbine.

[0039] The rotor blade used as lever arm 510 is a previously used rotor blade that was previously used in a wind turbine and / or is defective and / or has been tested using the rotor blade test stand.

[0040] The test device 500 further comprises a drive device 700 for applying a torque to the second rotary bearing component 220, which is rigidly connected to the second transmission bearing component 320, so that the second rotary bearing component 220 can be set into rotation during the application of the load to the rotary bearing, which corresponds to the operating conditions of the main bearing of a wind turbine.

[0041] The drive device 700 comprises a motor, in particular an electric motor, and engages a drive feature 631 (e.g., teeth) of the third bearing adapter 630 by means of a drive belt acting as a transmission element 710. The drive device 700 may also include an alternative transmission element, such as a gear or an arrangement of gears.

[0042] The test procedure includes applying the load required for testing to the rotary bearing 200 using the load transfer device 500 and (if applicable, optionally) applying a torque to the second rotary bearing component 220 using the drive device 700.

[0043] For statically and / or dynamically applying the forces or moments necessary to generate the load to the lever arm 510 of the load transmission device 500, the test device 100 includes a load application device 800. The required forces or moments can be applied statically and / or dynamically by means of the load application device. The load application device 800 comprises several load frames 840 configured to apply bending moments to the lever arm 510, as used in rotor blade testing on the rotor blade test stand. The load frames 840 include internal profiles 841 for positively engaging a rotor blade used as a lever arm 510.

[0044] The load application device comprises, for example, hydraulic cylinders 810 and winches 820 for generating the forces or moments, as well as cables 830 for transmitting the force or moment to the load transmission device 500. Instead of (or in addition to) the cables 830, chains and / or transmission rods may be provided, for example. The load frames 840 are coupled to the hydraulic cylinders 810 or the winches 820 of the load application device 800 by means of the cables 830.

[0045] The load introduction device 800 further comprises locking devices for statically maintaining the load. These locking devices may include, for example, lockable winches and / or a device for mechanically jamming the hydraulic cylinders and / or the associated cables 830.

[0046] The test device 500 further comprises a rotationally fixed suspension of the load transfer device 500. The rotationally fixed suspension is formed by two hydraulically interconnected hydraulic cylinders 810 of the load introduction device 800, designed as double-chamber hydraulic cylinders, which are connected by means of cables 830 to a load frame 840 – thus rotationally fixed – by means of respective cables 830. In addition to or as an alternative to the rotationally fixed suspension, a rotationally fixed support, for example by means of rigid elements such as connecting rods, may be provided.

[0047] The test device 500 comprises several sensors 900, forming a sensor arrangement for acquiring measured values ​​that correspond to, or provide information about, the parameters of the rotary bearing under load. The sensor arrangement can be configured, for example, to detect loads, such as by means of load cells and / or by evaluating hydraulic parameters of hydraulic cylinders. The sensor arrangement can be configured to detect vibrations, deformations, and / or temperatures. The sensor arrangement can be configured to detect torques, for example, based on the drive currents required to operate the drive device.The sensors 900 are accordingly arranged at various points on the test device 100, for example on components of the rotary bearing 200 and the transmission bearing 300, on the bearing adapters 610, 620, 630, on the holding block 400, on the load transmission device 500, on the load introduction device 800, on the drive device 700, etc.

[0048] The test device 100 (and the corresponding test procedure) is designed for the simultaneous testing of the aforementioned (first) rotary bearing 200 and a further (second) rotary bearing. For example, the transmission bearing 300 itself is a (second) rotary bearing to be tested. The second rotary bearing (transmission bearing 300) is identical in construction to the rotary bearing 200, but can also be different from it. The rotary bearings 200 and 300 are arranged in a back-to-back configuration (i.e., in an arrangement inverted relative to each other along the axis of rotation 110) for simultaneous testing. List of reference symbols: 100 test devices, 110 Rotation axis, 200 swivel bearings, 210 first rotary bearing component, 220 second rotary bearing component, 230 tapered rollers, 300 transfer warehouses, 310 first transmission bearing component, 320 second transmission bearing component, 400 retaining block, 410 Mounting surface, 500 load transfer device, 510 Lever arm, 610 first bearing adapter, 620 second bearing adapter, 630 third bearing adapter, 631 Attack feature, 700 drive device, 710 transmission element, 800 Load introduction device, 810 hydraulic cylinders, 820 winch, 830 rope, 840 load frames, 841 Internal profile, 900 Sensor.

Claims

[1] Testing device (100) for testing a rotary bearing (200), in particular a main bearing comprising at least one rolling bearing for a wind turbine, under a load, wherein the rotary bearing (200) comprises a first rotary bearing component (210) and a second rotary bearing component (220) rotatable relative to the first rotary bearing component (210) about a rotation axis (110), wherein the testing device (100) comprises: a transmission bearing (300) with a first transmission bearing component (310) and a second transmission bearing component (320) rotatable about the rotation axis (110) relative to the first transmission bearing component (310), a stationary holding block (400), in particular a reaction block of a rotor blade test stand, which can be or is rigidly connected to the first rotary bearing component (210) or the first transmission bearing component (310), and a load transmission device (500) for applying the load to the pivot bearing (200), wherein the load transmission device (500) is rigidly connectable or connected to that component from the group consisting of the first pivot bearing component (210) and the first transmission bearing component (310) which is not rigidly connected to the holding block (400), and the second transmission bearing component (320) is rigidly connectable or connected to the second pivot bearing component (220). [2] Testing device (100) according to claim 1, wherein the load transmission device (500) comprises a lever arm (510), in particular a rotor blade or at least one tower segment for a wind turbine, wherein the lever arm (510) has preferably been previously used in a wind turbine and / or is defective and / or has been tested by means of the rotor blade test bench. [3] Testing device (100) according to one of the preceding claims, wherein the testing device (100) is configured for simultaneous testing of the aforementioned rotary bearing (200) and a further rotary bearing (200), in particular such that the further rotary bearing (200) is used as a transmission bearing (300). [4] Testing device (100) according to one of the preceding claims, further comprising: a drive device (700) for applying a torque to the second rotary bearing component (220) rigidly connected to the second transmission bearing component (320) such that the second rotary bearing component (220) can be set in rotation while the rotary bearing (200) is being subjected to the load, wherein the drive device (700) acts in particular on a bearing adapter (610, 620, 630) connecting the second rotary bearing component (220) to the second transmission bearing component (320). [5] Testing device (100) according to one of the preceding claims, further comprising: a load introduction device (800) for applying a force and / or a moment to the load transmission device (500) to generate the load, wherein the load introduction device (800) comprises in particular at least one hydraulic cylinder (810) and / or at least one cable winch (820). [6] Testing device (100) according to claim 5, wherein the load introduction device (800) comprises at least one load frame configured to apply a bending moment to a rotor blade. [7] Test device (100) according to claim 5 or 6, wherein the load introduction device (800) comprises a blocking device for statically maintaining the load. [8] Testing device (100) according to one of the preceding claims, comprising a rotationally fixed suspension and / or support of the load transmission device (500), wherein the rotationally fixed suspension and / or support comprises in particular two crosswise hydraulically connectable or connected double-chamber hydraulic cylinders (810). [9] Testing device (100) according to one of the preceding claims, comprising at least one bearing adapter (610, 620, 630) for rigidly connecting the first rotary bearing component (210) or the first transmission bearing component (310) to the holding block (400) and / or for rigidly connecting the first transmission bearing component (310) or the first rotary bearing component (210) to the load transmission device (500) and / or for rigidly connecting the second rotary bearing component (220) to the second transmission bearing component (320). [10] Test method for testing a rotary bearing (200), in particular a main bearing comprising at least one rolling bearing for a wind turbine, under a load, wherein the pivot bearing (200) comprises a first pivot bearing component (210) and a second pivot bearing component (220) rotatable relative to the first pivot bearing component (210) about a rotation axis (110), wherein the testing method comprises the following steps: rigidly connecting the second pivot bearing component (220) to a second transmission bearing component (320) of a transmission bearing (300), which is rotatable about the rotation axis (110) relative to a first transmission bearing component (310) of the transmission bearing (300), rigidly connecting the first pivot bearing component (210) or the first transmission bearing component (310) to a stationary holding block (400), in particular a reaction block of a rotor blade test bench, rigidly connecting that component from the group consisting of the first pivot bearing component (210) and the first transmission bearing component (310) which is not rigidly connected to the holding block (400) to a load transmission device (500), which in particular comprises a rotor blade or at least one tower segment for a wind turbine, and Applying the load to the pivot bearing (200) by means of the load transfer device (500).

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