Gearbox Lubrication Pump Control for Low-Speed Oil Pressure
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Solution Overview
Problem
Current wind turbine gearbox systems face insufficient lubrication during low input speed conditions, leading to potential oil leakage and increased energy consumption when the mechanical pump's displacement is designed for rated conditions, and insufficient lubrication when designed for low-speed situations.
Innovation Solution
A control device with a mechanical pump having two-stage displacement, where a sensor module detects oil pressure and input speed to adjust the pump's operation between first-stage and second-stage displacements, ensuring adequate lubrication without excessive oil pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mechanical pump displacement is designed for rated operating conditions, then the lubrication is sufficient at rated speed, but the oil supply becomes insufficient at low input speed
Solution Approach 1:
The mechanical pump is designed with variable displacement capability, allowing it to switch between first-stage displacement and second-stage displacement based on operating conditions. The control module adjusts the pump displacement dynamically according to input speed feedback, ensuring sufficient oil supply across the entire operating range from low speed to rated speed.
Solution Approach 2:
The pump displacement parameter is changed based on operating conditions. At low input speed, the pump operates at second-stage displacement (larger displacement) to provide sufficient flow. At rated operating conditions, it switches to first-stage displacement (smaller displacement) to prevent excessive flow and high oil pressure.
2Reliability
If the mechanical pump displacement is designed for low input rotation speed, then the oil supply is sufficient at low speed, but excessive oil flow and high oil pressure occur at rated operating conditions
Solution Approach 1:
The pump system dynamically adjusts displacement based on operating conditions. The control module receives input speed signals and switches between first-stage and second-stage displacement accordingly, preventing high oil pressure at rated speed while maintaining sufficient lubrication at low speed.
Solution Approach 2:
The control module uses feedback from input speed detection to adjust pump displacement. When input speed reaches rated conditions, the system switches to first-stage displacement to reduce oil flow and prevent excessive oil pressure. This closed-loop control ensures oil pressure remains within safe limits across all operating conditions.
3Reliability
If the mechanical pump displacement is increased to ensure lubrication at low speed, then lubrication is improved, but energy consumption increases at rated operating conditions
Solution Approach 1:
The pump operates at second-stage displacement (higher energy consumption) only when necessary for low-speed lubrication. At rated operating conditions, it switches to first-stage displacement (lower energy consumption), optimizing the energy-lubrication trade-off dynamically based on actual operating requirements.
Data Source
AI summary
A control device for a gearbox which includes a mechanical pump and an electric pump, the mechanical pump having a first-stage displacement and a second-stage displacement, and the first-stage displacement being less than the second-stage displacement, the control device including a sensor module for detecting an oil pressure of a lubricating oil of the gearbox and a mechanical pump control module for, when the oil pressure is above an oil pressure threshold, controlling the mechanical pump to operate at the first-stage displacement, and when the oil pressure is below the oil pressure threshold, controlling the mechanical pump to operate at the second-stage displacement.