风力发电机变桨轴承研究分析
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摘要
风力发电机组中变桨轴承作为风力发电机专用轴承之一,其使用性能的好坏、寿命长短均关系到风力发电机的正常运行、发电效率等。由于变桨轴承尺寸较大,结构及受力复杂,对其设计生产的难度也相对较大,一般国内生产的风电轴承性能和使用寿命都很难达到要求。论文以德国船级社风力发电机组认证规范及欧洲规范为依据,结合现代设计理论及分析方法,对某MW级变桨轴承进行相关研究分析,为变桨轴承的设计与生产提供参考,具有理论意义和工程实用价值。
论文主要研究内容如下:
①采用有限元方法对变桨轴承的滚道、轮齿啮合部位进行了强度分析,对分析结果作了说明,为变桨轴承在受载下的载荷分布提供参考。
②在建模的时候利用GAP单元代替滚珠对轴承进行简化建模,采用理论计算和有限元结果进行对比,证实了这种简化建模方法的正确性,为以后复杂滚动轴承建模提供一种有效的简化方法。
③对变桨轴承应力最大点做疲劳寿命分析,根据GL规范设定变桨轴承材料的S-N曲线,同时对疲劳载荷谱进行转换,利用MSC.Fatigue软件计算得到变桨轴承总的疲劳损伤值,这种疲劳方法为轴承的疲劳计算提供一种新的思路。
④对变桨轴承内圈螺栓的强度和疲劳做了计算,并采用有限元方法对变桨轴承上螺栓作了优化。结果表明螺栓强度和疲劳满足要求,有限元方法更能真实反应螺栓的应力分布,同时说明螺栓优化方式合理。
Pitch bearing is one of the special bearings in the wind turbine, the performance and life of which can influnce the running and power generation efficiency of the wind turbine. Due to the pitch bearing’s large size,complex structure and loads, there is greater difficulty of design and production for the pitch bearing. The performance and fatigue life of wind turbine bearing produced in China are difficult to meet requirement. This paper analysed pitch bearing by using the modern design theorys and analysis methods,according to the Germanischer Lloyd Guideline for Certification of Wind Turbine and Euro Code.It can provide the reference for designing and producting to pitch bearing, and has theoretical and practical engineering value.
Main researches covered in this paper are as follows:
①The article analysed the strength of raceway of pitch bearing and area of gear contact, and described the results of analysis, meanwhile, provied the reference for the load distribution of pitch bearing.
②Using the GAP element instead ball to simplify modeling for rolling bearing, comparing the results of FEA with theoretical results to confirm the correctness of simplified modeling. It provides an effective simplified modeling method for complex rolling bearing.
③Analysing the fatigue life of pitch bearing’s point of maximum stress, setting the S-N curve for the meterial of pitch bearing according to the GL specification, making the conversion of fatigue load spectrum, and using the MSC.Fatigue software to calculate the total fatigue damage value of pitch bearing. This fatigue method provides a new way of thinking to calculate the bearing’life.
④The article computed the strength and fatigue of the inner bolts of pitch bearing, and optimized the bolts of pitch bearing with the finite element method.The result illustrated that the strength and fatigue satisfied the requirement,the finite element method can reflect the stress distribution of bolts factually,and veritified the reasonable optimization for bolts.
论文主要研究内容如下:
①采用有限元方法对变桨轴承的滚道、轮齿啮合部位进行了强度分析,对分析结果作了说明,为变桨轴承在受载下的载荷分布提供参考。
②在建模的时候利用GAP单元代替滚珠对轴承进行简化建模,采用理论计算和有限元结果进行对比,证实了这种简化建模方法的正确性,为以后复杂滚动轴承建模提供一种有效的简化方法。
③对变桨轴承应力最大点做疲劳寿命分析,根据GL规范设定变桨轴承材料的S-N曲线,同时对疲劳载荷谱进行转换,利用MSC.Fatigue软件计算得到变桨轴承总的疲劳损伤值,这种疲劳方法为轴承的疲劳计算提供一种新的思路。
④对变桨轴承内圈螺栓的强度和疲劳做了计算,并采用有限元方法对变桨轴承上螺栓作了优化。结果表明螺栓强度和疲劳满足要求,有限元方法更能真实反应螺栓的应力分布,同时说明螺栓优化方式合理。
Pitch bearing is one of the special bearings in the wind turbine, the performance and life of which can influnce the running and power generation efficiency of the wind turbine. Due to the pitch bearing’s large size,complex structure and loads, there is greater difficulty of design and production for the pitch bearing. The performance and fatigue life of wind turbine bearing produced in China are difficult to meet requirement. This paper analysed pitch bearing by using the modern design theorys and analysis methods,according to the Germanischer Lloyd Guideline for Certification of Wind Turbine and Euro Code.It can provide the reference for designing and producting to pitch bearing, and has theoretical and practical engineering value.
Main researches covered in this paper are as follows:
①The article analysed the strength of raceway of pitch bearing and area of gear contact, and described the results of analysis, meanwhile, provied the reference for the load distribution of pitch bearing.
②Using the GAP element instead ball to simplify modeling for rolling bearing, comparing the results of FEA with theoretical results to confirm the correctness of simplified modeling. It provides an effective simplified modeling method for complex rolling bearing.
③Analysing the fatigue life of pitch bearing’s point of maximum stress, setting the S-N curve for the meterial of pitch bearing according to the GL specification, making the conversion of fatigue load spectrum, and using the MSC.Fatigue software to calculate the total fatigue damage value of pitch bearing. This fatigue method provides a new way of thinking to calculate the bearing’life.
④The article computed the strength and fatigue of the inner bolts of pitch bearing, and optimized the bolts of pitch bearing with the finite element method.The result illustrated that the strength and fatigue satisfied the requirement,the finite element method can reflect the stress distribution of bolts factually,and veritified the reasonable optimization for bolts.
引文
[1]美国"美国《油气"油气杂志》于2010年12月6日发布世界年度储量调查/data/"统计报告[EB/OL].http://fdbbs.bjx.com.cn/viewthread.php.
[2]陈晖.全球风能理事会发布《全球风能展望2010》[EB/OL]. www.istis.sh.cn/list/list.aspx?id=6834(2010-10-15).
[3]周飞.水平轴风力发电机偏航轴承的性能分析与研究[D].华北电力大学,2008.12.
[4]叶军.破解风电轴承国产化难题[J].现代制造.2009,29:7.
[5]何加群.风电轴承要补上研发这一课[J].现代制造. 2009,29:6.
[6]陈龙,赵联春等.变桨轴承载荷分布分析[J].轴承. 2010,1:1-4,9.
[7]王思明,史小辉等.风力发电机变桨轴承微动磨损与防护[J].润滑与密封. 2009,12:110-112,119.
[8]张锁怀,郭军.风力发电机桨叶轴承载荷分析模型的研究[J].机械设计与研究.2009,8:116-119.
[9]叶航治.风力发电机组控制技术[M].北京:机械工业出版社.2002.
[10] Tony Burton,David Sharpe, Nick Jenkins,Ervin Bossanyi. Wind energy handbook[M]. John Wiley & Sons,LTD,2001.
[11]方成刚,高学海等.风电转盘轴承的设计与制造[J].轴承.2009,9:57-62.
[12]万长森.滚动轴承的分析方法[M].北京:机械工业出版社,1987.3.
[13] Hertz H.The contact of elastic solids.J.Reine Angew.Math,1881,(92):156-171.
[14]冈本纯三.球轴承的设计计算[M].北京:机械工业出版社,2003.4:6-7.
[15] G. Lundberg & A. Palmgren, Dynamic Capacity of Rolling Bearings, Acta Polytechnica No07,1947.
[16]龙振宇.机械设计[M].北京:机械工业出版社,2008.8.
[17] Martin O.L.Hansen.Aerodynamics of wind turbines[M].USA,2008.
[18]张锁怀,郭军.风力发电机桨叶轴承载荷分析模型的研究[J].机械设计与研究. 2009.8(4):116-119.
[19]黄国权.有限元法基础及ANSYS应用[M].机械工业出版社.2004,6.
[20] Stribeck R.Ball bearing for various loads.Transactions of the ASME,1907,(29):420-463.
[21] Sjov?ll H.The load distribution within ball and roller bearings under given external radial and axial load.Teknisk Tidskrift Mek,1933.
[22] Rumbarger J.Thrust bearing with eccentric loads.Machine design,1962.
[23] A. Palmgren.Ball and Roller Bearing Engineering. Transactions of ASME. Journal of BasicEngineering.1911,Vol.44:220-254.
[24] Jones A B.Bll Motion and Slitting Frition in Ball Bearings[J].Journal of Basic Engineering,1959,81:1-21.
[25]孙雪.某履带式装甲车悬挂系统的滚针轴承分析[D].沈阳理工大学.2008,12.
[26] Walters C T.The Dynamics of Ball Bearings.Journal of Lubrication Technelogy,Transactions of the ASME,1971,(93):1-10.
[27]张洪武,关振群等。有限元分析与CAE技术基础[M].北京:清华大学出版社,2004.1.
[28]陈火红,杨剑等.新编Marc有限元实例教程[M].北京:机械工业出版社,2007.
[29]陈达亮,郝志勇.GAP单元在气门弹簧动态特性有限元分析中的应用[J].拖拉机与农用运输车,2004(2):24-26.
[30]王国林,张建,等.基于GAP单元的车架有限元分析[J].浙江大学学报,2008,29(3):206-209.
[31]皮亚南,董懿琼,等.滚动轴承保持架不稳定性分析[J].江西科学,2008,10(5):770-773.
[32] Tedric A.Harris,Michael N.Kotzalas.Advanced concepts of bearing technology[M].Taylor & Francis Group,LLC,2007.
[33] Jose Ignacio Amasorrain,Xabier Sagartzazu.Load distribution in a four contact-point slewing bearing[J].Mechanism and Machine Theorz 38(2003)479-496.
[34]谢伟松等.数值分析[M].天津:天津大学出版社,2000.
[35]傅祥炯.结构疲劳与断裂[M].西北工业大学出版社,1995.12.
[36]王国军. MSC.Fatigue疲劳分析实例指导教程[M].北京:机械工业出版社,2009.1.
[37] Germanischer Lloyd Industrial Services GmbH.Guideline for the Certification of Wind Turbines[S]. Germany,2010.
[38] G?ncz,P.Glodez,S.Calculation model for pre-stressed bolted joints of slewing bearings[J].Advanced Engineering,3(2009)2:175-186.
[39] Zouhair Chaib,Alain Daidié,Dimitri Leray.Screw behavior in large diameter slewing bearing assemblies:numerical and experimental analyses[J].Int J Interact Des Manuf (2007)1:21-31.
[40] Aurelian Badean,Dimitri Leray,Jean Guillot.Bolted joints for very large bearings-numerical model development[J].Finite Elements in Analysis and Design 42(2006):298-313.
[41]徐立民,陈卓.回转支承[M].安徽:安徽科学技术出版社. 1988.12.
[42]龙振宇.机械设计[M].北京:机械工业出版社. 2001.6.
[2]陈晖.全球风能理事会发布《全球风能展望2010》[EB/OL]. www.istis.sh.cn/list/list.aspx?id=6834(2010-10-15).
[3]周飞.水平轴风力发电机偏航轴承的性能分析与研究[D].华北电力大学,2008.12.
[4]叶军.破解风电轴承国产化难题[J].现代制造.2009,29:7.
[5]何加群.风电轴承要补上研发这一课[J].现代制造. 2009,29:6.
[6]陈龙,赵联春等.变桨轴承载荷分布分析[J].轴承. 2010,1:1-4,9.
[7]王思明,史小辉等.风力发电机变桨轴承微动磨损与防护[J].润滑与密封. 2009,12:110-112,119.
[8]张锁怀,郭军.风力发电机桨叶轴承载荷分析模型的研究[J].机械设计与研究.2009,8:116-119.
[9]叶航治.风力发电机组控制技术[M].北京:机械工业出版社.2002.
[10] Tony Burton,David Sharpe, Nick Jenkins,Ervin Bossanyi. Wind energy handbook[M]. John Wiley & Sons,LTD,2001.
[11]方成刚,高学海等.风电转盘轴承的设计与制造[J].轴承.2009,9:57-62.
[12]万长森.滚动轴承的分析方法[M].北京:机械工业出版社,1987.3.
[13] Hertz H.The contact of elastic solids.J.Reine Angew.Math,1881,(92):156-171.
[14]冈本纯三.球轴承的设计计算[M].北京:机械工业出版社,2003.4:6-7.
[15] G. Lundberg & A. Palmgren, Dynamic Capacity of Rolling Bearings, Acta Polytechnica No07,1947.
[16]龙振宇.机械设计[M].北京:机械工业出版社,2008.8.
[17] Martin O.L.Hansen.Aerodynamics of wind turbines[M].USA,2008.
[18]张锁怀,郭军.风力发电机桨叶轴承载荷分析模型的研究[J].机械设计与研究. 2009.8(4):116-119.
[19]黄国权.有限元法基础及ANSYS应用[M].机械工业出版社.2004,6.
[20] Stribeck R.Ball bearing for various loads.Transactions of the ASME,1907,(29):420-463.
[21] Sjov?ll H.The load distribution within ball and roller bearings under given external radial and axial load.Teknisk Tidskrift Mek,1933.
[22] Rumbarger J.Thrust bearing with eccentric loads.Machine design,1962.
[23] A. Palmgren.Ball and Roller Bearing Engineering. Transactions of ASME. Journal of BasicEngineering.1911,Vol.44:220-254.
[24] Jones A B.Bll Motion and Slitting Frition in Ball Bearings[J].Journal of Basic Engineering,1959,81:1-21.
[25]孙雪.某履带式装甲车悬挂系统的滚针轴承分析[D].沈阳理工大学.2008,12.
[26] Walters C T.The Dynamics of Ball Bearings.Journal of Lubrication Technelogy,Transactions of the ASME,1971,(93):1-10.
[27]张洪武,关振群等。有限元分析与CAE技术基础[M].北京:清华大学出版社,2004.1.
[28]陈火红,杨剑等.新编Marc有限元实例教程[M].北京:机械工业出版社,2007.
[29]陈达亮,郝志勇.GAP单元在气门弹簧动态特性有限元分析中的应用[J].拖拉机与农用运输车,2004(2):24-26.
[30]王国林,张建,等.基于GAP单元的车架有限元分析[J].浙江大学学报,2008,29(3):206-209.
[31]皮亚南,董懿琼,等.滚动轴承保持架不稳定性分析[J].江西科学,2008,10(5):770-773.
[32] Tedric A.Harris,Michael N.Kotzalas.Advanced concepts of bearing technology[M].Taylor & Francis Group,LLC,2007.
[33] Jose Ignacio Amasorrain,Xabier Sagartzazu.Load distribution in a four contact-point slewing bearing[J].Mechanism and Machine Theorz 38(2003)479-496.
[34]谢伟松等.数值分析[M].天津:天津大学出版社,2000.
[35]傅祥炯.结构疲劳与断裂[M].西北工业大学出版社,1995.12.
[36]王国军. MSC.Fatigue疲劳分析实例指导教程[M].北京:机械工业出版社,2009.1.
[37] Germanischer Lloyd Industrial Services GmbH.Guideline for the Certification of Wind Turbines[S]. Germany,2010.
[38] G?ncz,P.Glodez,S.Calculation model for pre-stressed bolted joints of slewing bearings[J].Advanced Engineering,3(2009)2:175-186.
[39] Zouhair Chaib,Alain Daidié,Dimitri Leray.Screw behavior in large diameter slewing bearing assemblies:numerical and experimental analyses[J].Int J Interact Des Manuf (2007)1:21-31.
[40] Aurelian Badean,Dimitri Leray,Jean Guillot.Bolted joints for very large bearings-numerical model development[J].Finite Elements in Analysis and Design 42(2006):298-313.
[41]徐立民,陈卓.回转支承[M].安徽:安徽科学技术出版社. 1988.12.
[42]龙振宇.机械设计[M].北京:机械工业出版社. 2001.6.