Remote vibration testing system for wind turbine gearboxes

Abstract

The present invention proposes a remote vibration test system for a gearbox of a wind power generating set, which relates to the technical field of testing a wind power generating set. The system includes a sensor group, a data collector, an industrial control computer, a wireless router, a portable computer, and a wind power generating set, and hydraulic elastic supports are provided on both sides of the wind power generating set to adjust the support pressure of the torque arm for the wind power generating set. The sensor group is configured to collect vibration acceleration signals and rotation speed signals of the wind power generating set, transmit them to the data collector, and transmit them to the industrial control computer through the signal processing of the data collector. The industrial control computer processes and analyzes the vibration data through the analysis software of the vibration test, and the portable computer operates the analysis software of the vibration test through the remote software to process and analyze the vibration data. The present invention can remotely collect vibration test data of the gearbox in real time during the operation of the wind power generating set, and finally obtain the effect of different elastic support pressures on the vibration of the gearbox through the data analysis.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This invention claims priority to a patent application of the People's Republic of China, bearing application number 202211314396.8 and title "Remote vibration test system for gearbox of wind power generation set", filed with the State Intellectual Property Office of the People's Republic of China on October 26, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to the technical field of generating set testing, and more particularly to a remote vibration testing system for a gearbox of a wind generating set. [Background technology]

[0003] The geographical location of the wind power generation set is remote, the environmental conditions are complicated, and the conditions it faces are constantly changing. As the main mechanical part that transmits power, the gearbox will cause vibration in the box due to the excitation action caused by the existence of the internal rotating mechanism, the rotation of the shaft and the meshing of the gears, etc., which is one of the main excitation sources of the vibration of the draft fan. In order to reduce the impact of the vibration of the gearbox box on the entire transmission chain, not only can the elastic support structure be adopted to block the transmission of vibration energy, but also the vibration of the box itself can be damped by installing an appropriate damper, so as to control the vibration transmission of the gearbox within a certain range and extend the operating life of the draft fan.

[0004] At present, there are three different elastic support methods according to the layout of the transmission chain of the draft fan: shell-type bearing type, stacked spring type, and hydraulic type. The design of the elastic support generally calculates the strength and rigidity based on the load of the draft fan to ensure that the elastic support has sufficient strength and rigidity, but the manufacturers of the elastic support do not consider the impact of the rigidity and strength of the elastic support on the gearbox and even the entire transmission chain, so it is necessary to study the impact of the elastic support on the vibration of the gearbox.

[0005] However, at present, there is not much research on the effect of the elastic support of the draft fan on the vibration of the gearbox, and most of it remains at the stage of theoretical analysis. Although there is research on the effect of the elastic support on the dynamic load characteristics of the draft fan from the perspective of simulation calculation, it is not possible to collect and analyze the vibration signals of the gearbox under different elastic support pressures from the perspective of vibration data from wind field tests. Summary of the Invention [Problem to be solved by the invention]

[0006] In view of the problems in the prior art, the objective of the present invention is to provide a remote vibration testing system for a gearbox of a wind power generating set, which can remotely collect vibration test data of the gearbox in real time during the operation of the wind power generating set, and finally obtain the effects of different elastic support pressures on the vibration of the gearbox through data analysis. [Means for solving the problem]

[0007] In order to achieve the above objectives, the present invention is realized by the following technical solutions: A remote vibration testing system for a gearbox of a wind power generating set, comprising: a sensor group, a data collector, an industrial control computer, a wireless router, a portable computer, and a wind power generating set; The data of the data collectors are respectively data-connected to the sensor group and the industrial control computer, the industrial control computer is data-connected to the wireless router, and the wireless router is data-connected to the portable computer by the wireless network; a hydraulic elastic support is provided on both sides of the wind power generating set, which is used to adjust the support pressure of the torque arm for the wind power generating set; the sensor group is installed in the wind power generating set, which is configured to collect and transmit the vibration acceleration signal and the rotation speed signal to the data collector, and transmit the same to the industrial control computer after the signal processing of the data collector; the vibration test analysis software is arranged in the industrial control computer, the industrial control computer processes and analyzes the vibration data by the vibration test analysis software, and the portable computer operates the vibration test analysis software by the remote software, thereby realizing the remote collection of the vibration test data of the gearbox of the wind power generating set, and processes and analyzes the vibration data after the data is collected.

[0008] Further, the wind power generation set includes a wind turbine, a main shaft, a gear box, and a generator, and the gear box includes a first-stage planetary carrier, a first-stage planetary sun gear, a second-stage planetary carrier, a second-stage planetary sun gear, a high-speed parallel-axis large gear shaft, and a high-speed parallel-axis small gear shaft, and the wind turbine is connected to the main shaft, and the main shaft is connected to the first-stage planetary carrier, the first-stage planetary sun gear is attached to the first-stage planetary carrier, the first-stage planetary sun gear is connected to the second-stage planetary carrier, and the second-stage planetary sun gear is attached to the second-stage planetary carrier. The main shaft is mounted on the planetary carrier, and the two-stage planetary sun gear is connected to the parallel-axis large gear shaft at high speed, and the large gear on the parallel-axis large gear shaft at high speed and the small gear on the parallel-axis small gear shaft at high speed are meshed and transmitted, and the parallel-axis small gear shaft at high speed is connected to the generator, and torque arms are provided on both sides of the gearbox, and hydraulic elastic supports are mounted on both sides of the gearbox by the torque arms, which are used to balance the torque load transmitted by the main shaft to the gearbox and make the gearbox vibrate within the range of the pre-compression amount of the hydraulic elastic supports.

[0009] Further, the sensor group includes a radial low frequency acceleration sensor of the first stage planet, a radial low frequency acceleration sensor of the second stage planet, a high speed parallel axis radial co-frequency acceleration sensor, a high speed parallel axis axial co-frequency acceleration sensor, and a photoelectric rotational speed sensor, wherein the radial low frequency acceleration sensor of the first stage planet is mounted radially of the first stage planet, the radial low frequency acceleration sensor of the second stage planet is mounted radially of the second stage planet and is used to collect vibration acceleration signals of the planetary stages, the high speed parallel axis radial co-frequency acceleration sensor is mounted radially of the high speed parallel axis downwind bearing in the gear box, the high speed parallel axis axial co-frequency acceleration sensor is mounted axially of the high speed parallel axis downwind bearing in the gear box and is used to collect vibration acceleration signals of the high speed parallel axis, and the photoelectric rotational speed sensor is mounted on the pinion shaft of the high speed parallel axis for collection and is used to collect rotational speed signals of the pinion shaft of the high speed parallel axis.

[0010] Furthermore, the hydraulic elastic support comprises an upper elastic body and a lower elastic body respectively installed in a sealed chamber, the upper elastic body and the lower elastic body are installed from top to bottom, one end of the torque arm is attached between the upper elastic body and the lower elastic body, and both the upper elastic body and the lower elastic body use damping pads with a metal frame structure.

[0011] In addition, the system further comprises a first hydraulic oil pipe and a second hydraulic oil pipe, the upper elastic body of the hydraulic elastic support on one side of the wind power generation set is connected to the lower elastic body of the hydraulic elastic support on the other side of the wind power generation set by the first hydraulic oil pipe, and the lower elastic body of the hydraulic elastic support on one side of the wind power generation set is connected to the upper elastic body of the hydraulic elastic support on the other side of the wind power generation set by the second hydraulic oil pipe.

[0012] Furthermore, the upper and lower elastic bodies each use a damping pad made of a metal rubber vulcanide.

[0013] In addition, the system further comprises a 4G network interface card installed in the wireless router for connecting to the industrial control computer and providing a wireless network signal.

[0014] In addition, the data collector is equipped with a built-in 16-way 24-bit AD acquisition channel, which is used to receive the vibration and rotation speed signals transmitted by the sensor group and connect to an industrial control computer via an Ethernet port.

[0015] Compared with the prior art, the beneficial effects of the present invention are that the present invention provides a remote vibration testing system for gearbox of wind power generation set, the vibration signal collected by the sensor group is transmitted to a data collector, and the signal is processed by the data collector before being transmitted to an industrial control computer, the vibration test analysis software is arranged in the industrial control computer, a 4G network interface card is inserted into the wireless router to provide a network signal to the industrial control computer, the portable computer operates the vibration test analysis software through the remote software, realizes the remote collection of vibration test data of the gearbox, and after data collection, performs remote post-processing analysis on the vibration data, and the engineer uses the vibration test analysis software to perform time domain analysis, frequency domain analysis, cepstrum analysis, envelope spectrum analysis, time-frequency domain analysis, etc., and finally obtains the effects of different elastic support pressures on the vibration of the gearbox.

[0016] From this, it can be seen that the present invention has significant substantial features and significant advances over the prior art, and the beneficial effects of its implementation are also obvious.

[0017] In order to more clearly describe the embodiments of the present invention or the technical solutions in the prior art, the following briefly describes the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only embodiments of the present invention, and those skilled in the art can obtain other drawings based on the drawings provided without paying creative labor. [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a structural diagram of a system according to a specific embodiment of the present invention; [Diagram 2] FIG. 2 is a schematic diagram of the structure of a wind power generating set according to a specific embodiment of the present invention; [Diagram 3] FIG. 2 is a schematic diagram of a hydraulic elastic support structure according to a specific embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, specific embodiments of the present invention will be described with reference to the drawings.

[0020] A remote vibration testing system for the gearbox of the wind power generating set shown in Figure 1, comprising a sensor group, a data collector, an industrial control computer, a wireless router, a 4G network interface card, a portable computer, and a wind power generating set.

[0021] The data of the data collector is respectively data-connected to the sensor group and the industrial control computer, the industrial control computer is data-connected to the wireless router, and the wireless router is data-connected to the portable computer by the wireless network. A 4G network interface card is installed in the wireless router to connect to the industrial control computer and provide a wireless network signal. The data collector is built-in with a 16-way 24-bit AD collection channel, which is used to receive the vibration and rotation speed signals transmitted by the sensor group and connect to the industrial control computer by the Ethernet port.

[0022] A hydraulic elastic support is provided on both sides of the wind power generating set, which is used to adjust the support pressure of the torque arm against the wind power generating set; The sensor group is installed in the wind power generating set, and is configured to collect vibration acceleration signals and rotation speed signals, transmit them to a data collector, and transmit them to an industrial control computer after signal processing by the data collector. Vibration test analysis software is arranged in the industrial control computer, and the industrial control computer processes and analyzes the vibration data through the vibration test analysis software. The portable computer operates the vibration test analysis software through the remote software, thereby realizing the remote collection of vibration test data of the gearbox of the wind power generating set, and processing and analyzing the vibration data after data collection.

[0023] As shown in FIG. 2, the wind power generation set includes a wind turbine 1, a main shaft 2, a gear box 21, and a generator 9. In the gear box 21, a first-stage planetary carrier 3, a first-stage planetary sun gear 4, a second-stage planetary carrier 5, a second-stage planetary sun gear 6, a high-speed parallel large gear shaft 7, and a high-speed parallel small gear shaft 8 are provided. The wind turbine 1 is connected to the main shaft 2, and the main shaft 2 is connected to the first-stage planetary carrier 3, and the first-stage planetary thick gear 4 is connected to the second-stage planetary carrier 5. The sun gear 4 is attached to the first-stage planetary planet carrier 3, the first-stage planetary sun gear 4 is connected to the second-stage planetary planet carrier 5, the second-stage planetary sun gear 6 is attached to the second-stage planetary planet carrier 5, the second-stage planetary sun gear 6 is connected to the parallel-axis large gear shaft 7 at high speed, the large gear of the parallel-axis large gear shaft 7 and the pinion of the parallel-axis high-speed pinion gear shaft 8 are meshed and transmitted, and the parallel-axis high-speed pinion gear shaft 8 is connected to a generator 9.

[0024] Torque arms 10 are provided on both sides of the gearbox 21, and hydraulic elastic supports 11 are attached to both sides of the gearbox 21 by the torque arms 10, and are used to balance the torque load transmitted by the main shaft to the gearbox 21 and to vibrate the gearbox 21 within the range of the pre-compression amount of the hydraulic elastic supports 11.

[0025] The sensor group includes a first planetary low-frequency radial acceleration sensor 12, a second planetary low-frequency radial acceleration sensor 13, a high-speed parallel-axis radial co-frequency acceleration sensor 14, a high-speed parallel-axis axial co-frequency acceleration sensor 15, and a photoelectric rotational speed sensor 16. The first stage planetary radial low frequency acceleration sensor 12 is mounted radially on the planetary carrier 3 of the first stage planetary, the second stage planetary radial low frequency acceleration sensor 13 is mounted radially on the planetary carrier 5 of the second stage planetary and used to collect vibration acceleration signals of the planetary stages, the high speed parallel axis radial co-frequency acceleration sensor 14 is mounted radially in the downwind bearing direction of the high speed parallel axis in the gear box 21, the high speed parallel axis axial co-frequency acceleration sensor 15 is mounted axially in the downwind bearing direction of the high speed parallel axis in the gear box 21 and used to collect vibration acceleration signals of the high speed parallel axis, and the photoelectric rotational speed sensor 16 is mounted on the pinion shaft 8 of the high speed parallel axis for collecting and used to collect rotational speed signals of the pinion shaft 8 of the high speed parallel axis.

[0026] For example, as shown in FIG. 3, the hydraulic elastic support 11 includes an upper elastic body 17 and a lower elastic body 18, which are respectively installed in a sealed chamber, the upper elastic body 17 and the lower elastic body 18 are installed from top to bottom, one end of the torque arm 10 is attached between the upper elastic body 17 and the lower elastic body 18, and both the upper elastic body 17 and the lower elastic body 18 use damping pads with a metal frame structure.

[0027] In addition, the two hydraulic elastic supports 11 are connected by a first hydraulic oil pipe 19 and a second hydraulic oil pipe 20. The upper elastic body 17 of the hydraulic elastic support 11 on one side of the wind power generation set is connected to the lower elastic body 18 of the hydraulic elastic support 11 on the other side of the wind power generation set by the first hydraulic oil pipe 19, and the lower elastic body 18 of the hydraulic elastic support 11 on one side of the wind power generation set is connected to the upper elastic body 17 of the hydraulic elastic support 11 on the other side of the wind power generation set by the second hydraulic oil pipe. When the gearbox 21 vibrates, the hydraulic elastic support 11 receives an external force, so the volume of its cavity changes, the hydraulic pressure in the cavity flows, the liquid flowing up and down is damped, the energy caused by the vibration is shielded and consumed, and a vibration damping effect is realized. By adjusting the elastic support pressure, the planetary stage of the gearbox that changes according to the pressure and the vibration test data of the parallel axis are collected at high speed.

[0028] When the system is operated, first, the five situations of adjusting the pressure of the hydraulic elastic support 11 are: the pressure value of the first hydraulic oil pipe is 0 bar, and the pressure value of the second hydraulic oil pipe is 0 bar; the pressure value of the first hydraulic oil pipe is 60 bar, and the pressure value of the second hydraulic oil pipe is 60 bar; the pressure value of the first hydraulic oil pipe is 0 bar, and the pressure value of the second hydraulic oil pipe is 120 bar; the pressure value of the first hydraulic oil pipe is 120 bar, and the pressure value of the second hydraulic oil pipe is 0 bar; the pressure value of the first hydraulic oil pipe is 120 bar, and the pressure value of the second hydraulic oil pipe is 0 bar; The pressure value of the loop is 120 bar;Then, the vibration signal collected by the sensor group is transmitted to the data collector, and the signal is processed by the data collector before being transmitted to the industrial control computer, and the vibration test analysis software is placed on the industrial control computer, and a 4G network interface card is inserted into the wireless router to provide a network signal to the industrial control computer, and the portable computer operates the vibration test analysis software through the remote software, and finally realizes the remote collection of the vibration test data of the gearbox, and after the data is collected, the vibration data is subjected to remote post-processing analysis. The specific analysis process is as follows:

[0029] According to the VDI3834 standard, the collected gearbox vibration data is subjected to time domain analysis, the main parameter indicators are the most significant, average value, variance, waveform, pulse, margin, kurtosis and other indicators, the characteristics of the data can be reflected by these indicators, and at the same time, it can be determined whether the gearbox operation exceeds the vibration limit, and the early signal characteristics can be more intuitively reflected. As for the frequency domain analysis, the frequency domain analysis converts the time domain signal into a frequency domain signal by Fourier transform, calculates the frequency of the rotation speed of the gearbox shaft system and the frequency of the gear meshing, analyzes the change range of the characteristic frequency, and can judge the type, degree and occurrence location of the vibration signal. As for the cepstrum analysis, the logarithmic spectrum of the vibration signal is subjected to Fourier transform again, and the signal spectrum contains For example, when a local fault occurs in a gear, a large number of sideband frequency components will be generated. As for the envelope spectrum analysis, the envelope spectrum is sensitive to the signal related to the impact force, and can extract the weak signal buried in the background noise, extract the periodic impact signal with small amplitude, and then perform spectrum analysis on the signal. As for the time-frequency domain analysis, when the time domain and frequency domain indicators cannot be effectively evaluated for the nonlinear non-stationary signal of the gearbox, the time-frequency domain analysis is adopted, which can realize the multi-scale analysis of the whole signal and local details, and has good time-frequency resolution, and is applied in the aspects of separating the characteristic frequency of the gearbox, extracting weak signals and evaluating early vibration signals, etc. Through the above analysis, the effects of different elastic support pressures on gearbox vibration are finally obtained.

[0030] The present invention will be further described in conjunction with the drawings and specific examples. It should be understood that these examples are used only to explain the present invention, rather than limiting the scope of the present invention. In addition, after reading the contents of the description of the present invention, those skilled in the art can make various changes or modifications to the present invention, and it should be understood that these equivalent forms are also included in the scope defined by the present application. [Explanation of symbols]

[0031] 1 windmill 2 spindle 3. Planet carrier for single-stage planetary gear 4. Single-stage planetary sun gear 5. Two-stage planetary carrier 6. Two-stage planetary sun gear 7 High speed parallel gear shaft 8 High speed parallel pinion shaft 9. Generator 10 Torque arm 11 Hydraulic elastic support 12. Low-frequency radial acceleration sensor for the first planetary stage 13 Two-stage planetary low-frequency radial acceleration sensor 14 High-speed, parallel-axis, radial co-frequency acceleration sensor 15 High-speed, parallel-axis, axially co-harmonic acceleration sensors 16 Photoelectric Rotational Speed ​​Sensor 17 Upper elastic body 18 Lower elastic body 19 First hydraulic oil pipe 20 No. 2 hydraulic oil pipe 21 Gear box

Claims

1. A remote vibration testing system for a gearbox of a wind power generating set, comprising: a sensor group; a data collector; an industrial computer; a wireless router; a portable computer; and a wind power generating set; The data of the data collectors are respectively connected to a sensor group and an industrial computer, the industrial computer is connected to a wireless router, and the wireless router is connected to a portable computer through a wireless network; Hydraulic elastic supports are provided on both sides of the wind power generating set, and are used to adjust the support pressure of the torque arm against the wind power generating set; The sensor group is installed in the wind power generating set, and is configured to collect vibration acceleration signals and rotation speed signals, transmit them to a data collector, and transmit them to an industrial computer after signal processing in the data collector. The industrial computer processes and analyzes the vibration data using vibration test analysis software. The portable computer operates the vibration test analysis software using remote software, thereby achieving remote collection of vibration test data of the gearbox of the wind power generating set, and processing and analyzing the vibration data after data collection. The wind power generating set comprises a wind turbine, a main shaft, a gearbox, and a generator, and the gearbox is provided with a first-stage planetary planet carrier, a first-stage planetary sun gear, a second-stage planetary planet carrier, a second-stage planetary sun gear, a high-speed parallel-axis large gear shaft, and a high-speed parallel-axis pinion shaft, the wind turbine is connected to the main shaft, the main shaft is connected to the first-stage planetary planet carrier, the first-stage planetary sun gear is attached to the first-stage planetary planet carrier, the first-stage planetary sun gear is connected to the second-stage planetary planet carrier, the second-stage planetary sun gear is attached to the second-stage planetary planet carrier, the second-stage planetary sun gear is connected to the high-speed parallel-axis large gear shaft, the large gear on the high-speed parallel-axis large gear shaft and the pinion on the high-speed parallel-axis pinion shaft mesh and transmit, and the high-speed parallel-axis pinion shaft is connected to the generator, Torque arms are provided on both sides of the gearbox, and hydroelastic supports are attached to both sides of the gearbox by the torque arms, and are used to balance the torque load transmitted by the main shaft to the gearbox and to vibrate the gearbox within the range of the pre-compression amount of the hydroelastic supports; the sensor group includes a first-stage planetary low-frequency radial acceleration sensor, a second-stage planetary low-frequency radial acceleration sensor, a wide-band acceleration sensor in the radial direction of a parallel axis at high speed and including high-frequency components, a wide-band acceleration sensor in the axial direction of a parallel axis at high speed and including high-frequency components, and a photoelectric rotational speed sensor; The radial low-frequency acceleration sensor of the first planetary gear is attached in the radial direction of the first planetary gear, The radial low-frequency acceleration sensor of the second-stage planetary is mounted in the radial direction of the second-stage planetary and is used to collect vibration acceleration signals of the planetary stage; a high-speed parallel shaft radial wideband acceleration sensor including high-frequency components mounted in a gearbox in a radial direction of the bearing in a downwind direction of the high-speed parallel shaft; a high-speed parallel shaft axial wideband acceleration sensor including high-frequency components mounted in a gearbox in an axial direction of the bearing in a downwind direction of the high-speed parallel shaft, for collecting a vibration acceleration signal of the high-speed parallel shaft; A remote vibration testing system for gearboxes of wind power generating sets, characterized in that a photoelectric rotational speed sensor is attached to a pinion shaft of a parallel shaft at high speed for collection, and is used to collect rotational speed signals of the pinion shaft of a parallel shaft at high speed.

2. 2. The remote vibration testing system for a gearbox of a wind power generation set according to claim 1, wherein the hydraulic elastic support comprises an upper elastic body and a lower elastic body respectively installed in a sealed chamber, the upper elastic body and the lower elastic body are installed from top to bottom, one end of the torque arm is attached between the upper elastic body and the lower elastic body, and both the upper elastic body and the lower elastic body use damping pads with a metal frame structure.

3. 3. The remote vibration testing system for gearboxes of wind power generating sets according to claim 2, characterized in that the hydraulic elastic support is further provided with a first hydraulic oil pipe and a second hydraulic oil pipe, the upper elastic body of the hydraulic elastic support on one side of the wind power generating set is connected to the lower elastic body of the hydraulic elastic support on the other side of the wind power generating set by the first hydraulic oil pipe, and the lower elastic body of the hydraulic elastic support on one side of the wind power generating set is connected to the upper elastic body of the hydraulic elastic support on the other side of the wind power generating set by the second hydraulic oil pipe.

4. 4. The remote vibration testing system for a gearbox of a wind power generating set according to claim 3, wherein the upper elastic body and the lower elastic body each use a damping pad made of a metal rubber sulfide.

5. The remote vibration testing system for a gearbox of a wind power generation set according to claim 1, characterized in that the system further comprises a 4G network interface card installed in a wireless router for connecting to an industrial computer and providing a wireless network signal.

6. The remote vibration testing system for a gearbox of a wind power generating set according to claim 1, characterized in that the data collector has a built-in 16-way 24-bit AD collection channel, which receives the vibration and rotation speed signals transmitted by the sensor group, and is used to connect to an industrial computer via an Ethernet port.

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