风电齿轮箱快速更换工艺方案研究及应用

发布时间：2019-06-19 07:20

【摘要】：近年来,我国风电产业得到了快速发展,风电机组装机量日益庞大。随着风力发电机组投运时间增长,其寿命期内的故障率也在逐步增加。齿轮箱是双馈型风电机组主传动链中的核心部件,当其发生故障后,由于受到机组空间结构和自身结构等因素的限制,齿轮箱的维修主要是采取主传动链整体下架的维修方式,这种方案工艺复杂、对操作人员的技术水平要求高、并且占用大量维修装备、维修周期较长,企业因此面临着巨大的维修成本压力。针对上述问题,本文以1.5MW和1.0MW两种双馈型风电机组为研究对象,从机组结构分析入手,提出了单独对齿轮箱快速更换的工艺方案。通过理论计算和实践验证,该方案安全可靠,工艺装备操作简便,能够满足实际工程需求,同时有效地缩短了齿轮箱的维修周期,既为厂家节约了齿轮箱维修成本,也为风电业主挽回了因故障停机造成的发电量损失,具有良好的经济效益。双馈型风电机组齿轮箱快速更换的工艺方案设计,主要是基于对风电机组系统安全性的考量:本文在通过GLBladed软件对1.5MW机组模型建立的基础之上,对工艺方案的安全性进行了评估,重点分析了齿轮箱更换前后对机组载荷的影响,并通过ANSYS Workbench数值模拟计算方法对机组关键部件进行了强度校核和模拟仿真。最后根据载荷计算结果和机组结构对方案中工艺装备进行了设计及加工制造。以上分析结论可以指导齿轮箱的空中更换工艺过程和编制齿轮箱更换工艺文件,该方案已经成功地应用于宁夏地区某风场1.5MW机组齿轮箱的更换作业。
[Abstract]:In recent years, the wind power industry in China has been developed rapidly, and the installed capacity of wind turbines is increasing day by day. With the increase of operation time of wind turbine, the failure rate of wind turbine during its life is also increasing gradually. Gearbox is the core component of the main transmission chain of double-feed wind turbine. After its failure, due to the limitation of unit spatial structure and its own structure and other factors, the maintenance of gearbox is mainly to adopt the maintenance mode of the main transmission chain as a whole. This scheme has complex process, high technical level requirements for operators, and occupies a large number of maintenance equipment, and the maintenance cycle is long. As a result, enterprises are facing huge pressure on maintenance costs. In order to solve the above problems, this paper takes two kinds of dual-feed wind turbines, 1.5MW and 1.0MW, as the research object, and puts forward the process scheme of rapid replacement of gearbox based on the analysis of unit structure. Through theoretical calculation and practice, it is proved that the scheme is safe and reliable, the operation of process equipment is simple, it can meet the actual engineering needs, and at the same time effectively shorten the maintenance cycle of gearbox, which not only saves the maintenance cost of gearbox for manufacturers, but also recovers the loss of power generation caused by fault shutdown for wind power owners, which has good economic benefits. The process scheme design of rapid replacement of double-feed wind turbine gearbox is mainly based on the consideration of the safety of wind turbine system. Based on the establishment of 1.5MW unit model by GLBladed software, the safety of the process scheme is evaluated, and the influence of gearbox replacement on unit load is analyzed in detail. The strength check and simulation of the key components of the unit are carried out by ANSYS Workbench numerical simulation method. Finally, according to the load calculation results and the unit structure, the process equipment in the scheme is designed and manufactured. The above analysis conclusions can guide the process of gearbox replacement in the air and compile the process documents of gearbox replacement. This scheme has been successfully applied to the replacement operation of 1.5MW unit gearbox in a wind farm in Ningxia.
【学位授予单位】：宁夏大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TM315

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