大功率齿轮调速装置关键设计技术研究
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摘要
大型齿轮调速传动装置是集机、电、液于一体的新型传动装置,其设计制造技术是一项复杂的综合技术,加上国外对我国的技术封锁限制,国内也缺乏系统的研究、设计、生产和实验,目前仅有少数企业在中小型产品方面进行仿制,大型高参数装置还依赖进口,特别是传递功率6000kW以上、转速5000-6650r/min,配套60万千瓦、100万千瓦超临界、超超临界火电锅炉给水泵机组的大功率齿轮传动调速装置目前完全从国外进口。本文以大功率齿轮调速传动装置为研究对象,运用现代设计计算方法对其内部高功率密度齿轮副轴系系统、叶轮工作腔液力传动系统、勺管位移—工作腔进油—勺管体排油控制系统等方面进行了较全面的研究,基本掌握了大功率、高速度齿轮传动、液力传动及控制系统组成的大型齿轮调速装置的关键设计制造技术,开发出了超临界、超超临界燃煤发电机组中高速重载大型机电液调速传动装置。论文研究内容涉及大型齿轮调速装置调试运行基本特性及工作匹配关系、轴系模态计算及滑动轴承承载能力分析、叶轮工作腔内流场数值模拟计算及工作油路系统控制等。主要研究内容及结论有：
(1)基于大型齿轮调速系统的传动结构形式,建立了轴系动力学模型,分别对主动齿轮轴、泵轮轴、涡轮轴以及主动齿轮轴与泵轮轴耦合状态进行了模态计算,从计算结果可以得出,主动齿轮与齿轮-泵轮轴组成的系统在工作时是安全的。基于不完全液体润滑轴承承载能力计算和液体润滑静压轴承承载能力计算两种方法分别对装置关键位置径向滑动轴承和止推滑动轴承等十个滑动轴承进行承载能力计算,提出了提高滑动轴承承载能力的途径。
(2)基于调速装置叶轮工作腔内流场液力传动特性,确定了内流场三维数值模拟计算方法,选取相邻三个叶片间的流体块作为研究对象,采用流体分析软件FLUENT进行计算,得到额定功率7334kW、输入转速1490r/min齿轮调速装置的制动、牵引和额定三个代表性工况充液率分别为40%、80%及100%时流场压力、速度分布及液相分布情况。并计算出力矩系数预测装置输出外特性曲线,经对比符合理想特性曲线。
(3)在工作叶轮三维实体模型基础上,对叶轮在循环流动的工作液体中受力情况进行了分析求解。分别针对泵轮和泵轮涡轮套连接体,应用不同有限元分析软件对叶轮进行有限元分析,得到了液体作用在叶轮壁壳内壁上的应力与位移分布情况,找出了叶轮应力最大部位,泵轮最大应力发生在叶片根部与内腔连接处。泵轮涡轮套连接体计算表明,涡轮套应力主要是内壁压力的影响,整个叶轮中最容易发生破坏的薄弱处位于涡套的中心圆处。
(4)基于大型复合式齿轮调速装置油路控制系统原理,推导了调速装置工作油量计算公式,进而得到了工作油量的计算方法。以额定功率7334kW大型齿轮调速装置为例,计算了不同速比下需要的工作油油量,得出当速比为0.667时,齿轮调速装置的最大功率损失约为工作机械功率的16%。绘制了工作油量与速比的关系曲线,当输出转速在20%—97%调节时,最大所需工作油量约为最小油量的5.25倍。分析了进油控制阀体通油面积、勺管移动位置及充液率的关系,实现了对勺管和油路系统的精确控制。
Large gear variable speed transmission device is a new equipment incorporated with mechanics, electricity and hydraulics as a whole, the technology of its design and manufacturing is a sophisticated and integrated technology. For the reason of foreign technology blockade restrictions to China and lacking of systematic research, design, production and experiments, only minor products are imitated in a few companies nowadays, while large-scale high-parameter device is still basically dependent on imports. In particular, high-power gear variable speed devices used for boiler feed water pump in the thermal power is fully imported from abroad, which are over6000kW and5000rpm to6650rpm, supporting600,000kilowatts or1000,000kilowatts of supercritical generator sets or even ultra supercritical generator sets. In this dissertation, with high-power gear variable speed device as the study object, applying modern design calculation methods, a comprehensive study about the internal shaft system with high power density, the hydraulic drive system of the impeller's working chamber and the control system of displacement of scoop tube, inlet oil of working chamber and outlet oil of scoop tube is fulfilled. The key design and manufacturing technology of large gear variable speed transmission device consisting of high-power, high-speed gear transmission, hydraulic transmission and control system are basically mastered, high-speed and heavy duty hydraulic adjustment speed transmission device used for supercritical or ultra-supercritical coal-fired generating units is developed. The research contents of this dissertation involve the basic characteristics of the commissioning and the working match relationships in the device, the shaft system model buliding and the sliding bearing capacity calculation, the flow field numerical simulation and analysis in the working chamber of the impeller and the working hydraulic control system. Main research and conclusions are as following:
(1) Based on the transmission structure of the large gear speed control system, the shaft system dynamics model is established and model calculations about gear shaft, pump shaft, turbine shaft and the coupling state of gear shaft and pump shaft are respectively accomplished. From the calculation results, it can be concluded that the system is safe while working. Based on two methods of incomplete liquid lubricated bearing capacity calculation and liquid lubrication hydrostatic bearing capacity calculation, the load capacity calculations of ten sliding bearings including radial sliding bearings and thrust sliding bearings of the device are finished. Also the suggestion methods to increase the load capacit of sliding bearingy are proposed.
(2) Based on the hydraulic transmission characteristics of flow field in the working chamber of the impeller, three-dimensional numerical simulation method of inner flow field is determined. Fluid blocks of adjacent three blades are selected as the research subjects and fluid analysis software FLUENT is used, the pressure, speed and liquid phase distribution are analysed, in which the rated power is7334kW, the input speed is1490r/min for gear speed device at three representative operating conditions such as braking, traction and nominal speed, where the filling rates are40%,80%and100%respectively. After calculating the torque coefficient, the output external characteristic curve can be predicted. By contrast, it is the ideal characteristic curve.
(3) On the basis of three-dimensional model of the impeller, the liquid forces of the impeller are analyzed. Aiming at the pump wheel and the assembly body of the pump wheel and turbine wheel sleeve, different finite element analysis softwares are applied to analyse the impeller, then the stress and displacement distribution on the impeller housing acted by the liquid are obtained, and the maximum stress point in the impeller is found. The maximum stress occurs at the location connected by the impeller blade root and the cavity. The calculations of turbine impeller sleeve connector body also show that the turbine sets stress has a great effect on the stress of inner wall, occurring at the center circle of vortex sets which are most likely destroyed throughout the impeller.
(4) Based on the oil control system theory, the formula of the speed device's working oil mass can be derived and then its calculation method is got. Taking the large gear variable speed transmission device with a rated power of7334kW for example, by calculating the required working oil mass under different ratios, it is found that the gear adjusting device's maximum power loss is about16percent of working mechanical power when the ratio is0.667. From the curve drawn between working oil and ratio, it can be seen that when the output speed is adjustable between20%-97%, the maximum required working oil mass is approximately5.25times the minimum oil mass. By analyzing the oil passing area of the inlet oil control valve, the location of displacement of scoop tube spoon tube and the filling rate, the precise control for the spoon tube and hydraulic system can be achieved.
(1)基于大型齿轮调速系统的传动结构形式,建立了轴系动力学模型,分别对主动齿轮轴、泵轮轴、涡轮轴以及主动齿轮轴与泵轮轴耦合状态进行了模态计算,从计算结果可以得出,主动齿轮与齿轮-泵轮轴组成的系统在工作时是安全的。基于不完全液体润滑轴承承载能力计算和液体润滑静压轴承承载能力计算两种方法分别对装置关键位置径向滑动轴承和止推滑动轴承等十个滑动轴承进行承载能力计算,提出了提高滑动轴承承载能力的途径。
(2)基于调速装置叶轮工作腔内流场液力传动特性,确定了内流场三维数值模拟计算方法,选取相邻三个叶片间的流体块作为研究对象,采用流体分析软件FLUENT进行计算,得到额定功率7334kW、输入转速1490r/min齿轮调速装置的制动、牵引和额定三个代表性工况充液率分别为40%、80%及100%时流场压力、速度分布及液相分布情况。并计算出力矩系数预测装置输出外特性曲线,经对比符合理想特性曲线。
(3)在工作叶轮三维实体模型基础上,对叶轮在循环流动的工作液体中受力情况进行了分析求解。分别针对泵轮和泵轮涡轮套连接体,应用不同有限元分析软件对叶轮进行有限元分析,得到了液体作用在叶轮壁壳内壁上的应力与位移分布情况,找出了叶轮应力最大部位,泵轮最大应力发生在叶片根部与内腔连接处。泵轮涡轮套连接体计算表明,涡轮套应力主要是内壁压力的影响,整个叶轮中最容易发生破坏的薄弱处位于涡套的中心圆处。
(4)基于大型复合式齿轮调速装置油路控制系统原理,推导了调速装置工作油量计算公式,进而得到了工作油量的计算方法。以额定功率7334kW大型齿轮调速装置为例,计算了不同速比下需要的工作油油量,得出当速比为0.667时,齿轮调速装置的最大功率损失约为工作机械功率的16%。绘制了工作油量与速比的关系曲线,当输出转速在20%—97%调节时,最大所需工作油量约为最小油量的5.25倍。分析了进油控制阀体通油面积、勺管移动位置及充液率的关系,实现了对勺管和油路系统的精确控制。
Large gear variable speed transmission device is a new equipment incorporated with mechanics, electricity and hydraulics as a whole, the technology of its design and manufacturing is a sophisticated and integrated technology. For the reason of foreign technology blockade restrictions to China and lacking of systematic research, design, production and experiments, only minor products are imitated in a few companies nowadays, while large-scale high-parameter device is still basically dependent on imports. In particular, high-power gear variable speed devices used for boiler feed water pump in the thermal power is fully imported from abroad, which are over6000kW and5000rpm to6650rpm, supporting600,000kilowatts or1000,000kilowatts of supercritical generator sets or even ultra supercritical generator sets. In this dissertation, with high-power gear variable speed device as the study object, applying modern design calculation methods, a comprehensive study about the internal shaft system with high power density, the hydraulic drive system of the impeller's working chamber and the control system of displacement of scoop tube, inlet oil of working chamber and outlet oil of scoop tube is fulfilled. The key design and manufacturing technology of large gear variable speed transmission device consisting of high-power, high-speed gear transmission, hydraulic transmission and control system are basically mastered, high-speed and heavy duty hydraulic adjustment speed transmission device used for supercritical or ultra-supercritical coal-fired generating units is developed. The research contents of this dissertation involve the basic characteristics of the commissioning and the working match relationships in the device, the shaft system model buliding and the sliding bearing capacity calculation, the flow field numerical simulation and analysis in the working chamber of the impeller and the working hydraulic control system. Main research and conclusions are as following:
(1) Based on the transmission structure of the large gear speed control system, the shaft system dynamics model is established and model calculations about gear shaft, pump shaft, turbine shaft and the coupling state of gear shaft and pump shaft are respectively accomplished. From the calculation results, it can be concluded that the system is safe while working. Based on two methods of incomplete liquid lubricated bearing capacity calculation and liquid lubrication hydrostatic bearing capacity calculation, the load capacity calculations of ten sliding bearings including radial sliding bearings and thrust sliding bearings of the device are finished. Also the suggestion methods to increase the load capacit of sliding bearingy are proposed.
(2) Based on the hydraulic transmission characteristics of flow field in the working chamber of the impeller, three-dimensional numerical simulation method of inner flow field is determined. Fluid blocks of adjacent three blades are selected as the research subjects and fluid analysis software FLUENT is used, the pressure, speed and liquid phase distribution are analysed, in which the rated power is7334kW, the input speed is1490r/min for gear speed device at three representative operating conditions such as braking, traction and nominal speed, where the filling rates are40%,80%and100%respectively. After calculating the torque coefficient, the output external characteristic curve can be predicted. By contrast, it is the ideal characteristic curve.
(3) On the basis of three-dimensional model of the impeller, the liquid forces of the impeller are analyzed. Aiming at the pump wheel and the assembly body of the pump wheel and turbine wheel sleeve, different finite element analysis softwares are applied to analyse the impeller, then the stress and displacement distribution on the impeller housing acted by the liquid are obtained, and the maximum stress point in the impeller is found. The maximum stress occurs at the location connected by the impeller blade root and the cavity. The calculations of turbine impeller sleeve connector body also show that the turbine sets stress has a great effect on the stress of inner wall, occurring at the center circle of vortex sets which are most likely destroyed throughout the impeller.
(4) Based on the oil control system theory, the formula of the speed device's working oil mass can be derived and then its calculation method is got. Taking the large gear variable speed transmission device with a rated power of7334kW for example, by calculating the required working oil mass under different ratios, it is found that the gear adjusting device's maximum power loss is about16percent of working mechanical power when the ratio is0.667. From the curve drawn between working oil and ratio, it can be seen that when the output speed is adjustable between20%-97%, the maximum required working oil mass is approximately5.25times the minimum oil mass. By analyzing the oil passing area of the inlet oil control valve, the location of displacement of scoop tube spoon tube and the filling rate, the precise control for the spoon tube and hydraulic system can be achieved.
引文
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