双馈型风电机组齿轮箱更换方案的设计及应用
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摘要
随着我国风电机组装机量的逐年增加,风力发电机组寿命期内的故障日益显著,尤其以齿轮箱为例的传动链故障居高不下,而齿轮箱及关键部件的维修因诸多原因的限制,常停留在整体下架维修的阶段。经考察,目前齿轮箱下架维修方案存在工艺复杂,维修费用高等特点。针对此问题,提出双馈型风电机组空中仅对齿轮箱进行下架的维修方案,并对方案中的更换工艺装备进行了设计和加工制造。最终采用此方案成功对宁夏地区某风场三菱1.0MW机组齿轮箱进行了空中更换。实践证明,该方案安全可靠、操作简便,能够满足实际工程需求,极大程度上节约了风电齿轮箱及关键部件维护的成本,为风电业主在大部件更换方面带来了很大的经济效益。
With the increase of the total installed capacity of wind turbines in China,the failure of wind turbines is becoming more and more obvious in the life-span,especially the gearbox has high failure rate as an example of the wind turbines transmission chain. However,the maintenance of the gearbox and its key components are often limited to the stage of under the wind turbines tower. After investigation,there are complicated processes and high maintenance costs for the current gearbox maintenance scheme. In view of this problem,this paper presents the up-tower maintenance scheme that only hanging off the gearbox from the DFIG-based wind turbines cabin,and the replacement process equipment in the scheme were designed and manufactured. Finally,one of the Mitsubishi 1.0MW gearbox in Ningxia wind farm was successfully replaced using the up-tower maintenance scheme mentioned above. Application of the replacement scheme,it proved that the proposed scheme is secure and reliable,simplified operation,and satisfied with the actual requirement. The replacement scheme proposed in this paper greatly saves the maintenance costs of wind turbine gearbox and its key components as well as brings great economic benefits for wind power owners in large parts maintenance of wind turbines.
With the increase of the total installed capacity of wind turbines in China,the failure of wind turbines is becoming more and more obvious in the life-span,especially the gearbox has high failure rate as an example of the wind turbines transmission chain. However,the maintenance of the gearbox and its key components are often limited to the stage of under the wind turbines tower. After investigation,there are complicated processes and high maintenance costs for the current gearbox maintenance scheme. In view of this problem,this paper presents the up-tower maintenance scheme that only hanging off the gearbox from the DFIG-based wind turbines cabin,and the replacement process equipment in the scheme were designed and manufactured. Finally,one of the Mitsubishi 1.0MW gearbox in Ningxia wind farm was successfully replaced using the up-tower maintenance scheme mentioned above. Application of the replacement scheme,it proved that the proposed scheme is secure and reliable,simplified operation,and satisfied with the actual requirement. The replacement scheme proposed in this paper greatly saves the maintenance costs of wind turbine gearbox and its key components as well as brings great economic benefits for wind power owners in large parts maintenance of wind turbines.
引文
[1]秦海岩.中国风电产业地图2015[A].中国可再生能源学会风能专业委员会,2015:16-25.(Qin Hai-yan.2015 China wind power industry map[A].Chinese Wind Energy Association,2015:16-25.)
[2]李辉,胡姚刚.大功率并网风电机组状态监测与故障诊断研究综述[J].电力自动化设备,2016(1):6-7.(Li Hui,Hu Yao-gang.Overview of condition monitoring and fault diagnosis for grid-connected high-power wind turbine unit[J].Electric Power Automation Equipment,2016(1):6-7.)
[3]中国船级社.风力发电机组规范[M].北京:人民交通出版社,2008.(Chinese classification society.Wind Turbine Standards[M].Beijing:China Communications Press,2008.)
[4]马世明.一种用于空中更换风机齿轮箱的装置:中国,201620108145.8[P].2016.06.29.(Ma Shi-ming.An air-replacement of equipment for wind turbine gearboxes:China,201620108145.8[P].2016.06.29.)
[5]陈超祥,叶修梓.SolidWorks高级教程简编(2015)[M].北京:机械工业出版社,2011.(Chen Chao-xiang,Ye Xiu-zi.SolidWorks Advanced Tutorial Compendium(2015)[M].Beijing:Machinery Industry Press,2011.)
[6]尹芳.零件强度仿真中简化建模法的有效性分析[J].机械设计与制造,2013(9):239-241.(Yin Fang.Effectiveness analysis of simplified model method in strength simulation of components[J].Machinery Design&Manufacture,2013(9):239-241.)
[7]许京荆编著.ANSYS Workbench工程实例详解[M].北京:人民邮电出版社,2015(5).(Xu Jing-jing.ANSYS Workbench Engineering Examples[M].Beijing:People’s Posts and Telecommunications Press,2015.05.)
[8]孙黎,王春秀.基于ANSYS的大型风电机组齿轮箱的低速轴有限元分析[J].机械设计与制造,2009(5):35-37.(Sun Li,Wang Chun-xiu.Finite element analysis of low-speed-axis in gearbox for large wind turbine unit based on ansys[J].Machinery Design&Manufacture,2009(5):35-37.)
[9]成大先.机械设计手册第五版[M].北京:化学工业出版社,2011.(Cheng Da-xian.Mechanical Design Manual[M].Beijing:Chemical Industry Press,2011.)
[2]李辉,胡姚刚.大功率并网风电机组状态监测与故障诊断研究综述[J].电力自动化设备,2016(1):6-7.(Li Hui,Hu Yao-gang.Overview of condition monitoring and fault diagnosis for grid-connected high-power wind turbine unit[J].Electric Power Automation Equipment,2016(1):6-7.)
[3]中国船级社.风力发电机组规范[M].北京:人民交通出版社,2008.(Chinese classification society.Wind Turbine Standards[M].Beijing:China Communications Press,2008.)
[4]马世明.一种用于空中更换风机齿轮箱的装置:中国,201620108145.8[P].2016.06.29.(Ma Shi-ming.An air-replacement of equipment for wind turbine gearboxes:China,201620108145.8[P].2016.06.29.)
[5]陈超祥,叶修梓.SolidWorks高级教程简编(2015)[M].北京:机械工业出版社,2011.(Chen Chao-xiang,Ye Xiu-zi.SolidWorks Advanced Tutorial Compendium(2015)[M].Beijing:Machinery Industry Press,2011.)
[6]尹芳.零件强度仿真中简化建模法的有效性分析[J].机械设计与制造,2013(9):239-241.(Yin Fang.Effectiveness analysis of simplified model method in strength simulation of components[J].Machinery Design&Manufacture,2013(9):239-241.)
[7]许京荆编著.ANSYS Workbench工程实例详解[M].北京:人民邮电出版社,2015(5).(Xu Jing-jing.ANSYS Workbench Engineering Examples[M].Beijing:People’s Posts and Telecommunications Press,2015.05.)
[8]孙黎,王春秀.基于ANSYS的大型风电机组齿轮箱的低速轴有限元分析[J].机械设计与制造,2009(5):35-37.(Sun Li,Wang Chun-xiu.Finite element analysis of low-speed-axis in gearbox for large wind turbine unit based on ansys[J].Machinery Design&Manufacture,2009(5):35-37.)
[9]成大先.机械设计手册第五版[M].北京:化学工业出版社,2011.(Cheng Da-xian.Mechanical Design Manual[M].Beijing:Chemical Industry Press,2011.)