风力发电机轴承试验机关键技术研究
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摘要
随着近些年能源短缺与经济社会发展之间矛盾的凸显,风电行业作为新能源行业的代表,已经步入发展的快车道。在中国,近五年来,风机容量已经从750KW等小型机组发展到1.5MW、3MW等中型和大型机组,并且个别公司已经研发出了6MW的机组。风力发电机运行条件恶劣,风机轴承作为风力发电机的重要部件,对其性能的测试尤其重要,因此需要开发一种测试风机轴承性能的设备——轴承试验机。本课题的任务是对3MW风力发电机轴承试验机关键部件的机械结构进行载荷分析和有限元分析,以满足测试风机轴承的要求。
首先,本论文在大量收集相近设备的资料后,最终确定了轴承试验机的总体设计方案,并利用三维建模软件PRO/E对设备进行了实体建模。本轴承试验机采用双轴卧式结构,此结构不但能够两端加载,减小了设备的整体尺寸,而且安装试验轴承更加方便。其次,依据动量理论、叶素理论、动量—叶素理论以及风机载荷的计算方法,得出了主轴轴承、变浆轴承和偏航轴承的轴向力、径向力以及倾覆力矩的载荷情况。最后,为了轴承试验机关键部件的强度、刚度校核与优化设计,应用有限元分析软件对3MW风力发电机轴承试验机关键部件——轴承支架及左侧、右侧加载支架的强度和动力学特性进行分析。在分析中,对增加支架壁厚和增加梯形筋板两种方案进行了比较,对比两种方案的利弊,并根据计算结果进行强度校核,还得出其前6阶固有频率和对应的振型,为轴承试验机支架结构优化设计提供了理论依据。最终确定了满足静力学分析和模态分析要求的支架结构。
With the conflict between the recent energy shortages and the economic development was highlighted, as the representative of new energy industry, wind power industry has entered the fast track of development. The last five years in China, wind turbine capacity has increased from 750KW to 1.5MW or 3MW, and a few companies have developed 6MW wind turbines. Wind turbine always run in complex environment, as key components, it is essential to test wind turbine bearings properties, so we need develop a testing machine to test their properties. To meet the test requirements of wind turbine bearings, the task of the subject is to do load analysis and finite element analysis to the key components of testing machine of 3MW wind turbine bearings.
At first, in this thesis, after collected a large number of information about the similar devices, ultimately, we determined the overall design of the testing machine and with the help of PRO/E, the three-dimensional model of this machine was established. The structure is horizontal type with double axes, this structure is not only can load on both ends, reducing the overall size of machine, but also more convenient when install the test bearings. Secondly, based on momentum theory, blade element theory, momentum-blade element theory, axial force, radial force and overturning moment of spindle bearings, pitch bearings and yaw bearings were calculated. At last, the static strength and dynamic properties of testing machine key components of 3MW wind turbine bearing were analyzed to obtain the strength and stiffness check as well as the optimizing design of key components of bearing testing machine. The program of increase in wall thickness and add the trapezoidal ribs were compared, through contrast the advantages and disadvantages of two programs, and the strength was checked and satisfied with the demand of material strength. The former five orders natural frequencies and corresponding modes were obtained, which provides scientific basis for future design. At last, the structure of frame which meets the static analysis and modal analysis requirements were supplied.
首先,本论文在大量收集相近设备的资料后,最终确定了轴承试验机的总体设计方案,并利用三维建模软件PRO/E对设备进行了实体建模。本轴承试验机采用双轴卧式结构,此结构不但能够两端加载,减小了设备的整体尺寸,而且安装试验轴承更加方便。其次,依据动量理论、叶素理论、动量—叶素理论以及风机载荷的计算方法,得出了主轴轴承、变浆轴承和偏航轴承的轴向力、径向力以及倾覆力矩的载荷情况。最后,为了轴承试验机关键部件的强度、刚度校核与优化设计,应用有限元分析软件对3MW风力发电机轴承试验机关键部件——轴承支架及左侧、右侧加载支架的强度和动力学特性进行分析。在分析中,对增加支架壁厚和增加梯形筋板两种方案进行了比较,对比两种方案的利弊,并根据计算结果进行强度校核,还得出其前6阶固有频率和对应的振型,为轴承试验机支架结构优化设计提供了理论依据。最终确定了满足静力学分析和模态分析要求的支架结构。
With the conflict between the recent energy shortages and the economic development was highlighted, as the representative of new energy industry, wind power industry has entered the fast track of development. The last five years in China, wind turbine capacity has increased from 750KW to 1.5MW or 3MW, and a few companies have developed 6MW wind turbines. Wind turbine always run in complex environment, as key components, it is essential to test wind turbine bearings properties, so we need develop a testing machine to test their properties. To meet the test requirements of wind turbine bearings, the task of the subject is to do load analysis and finite element analysis to the key components of testing machine of 3MW wind turbine bearings.
At first, in this thesis, after collected a large number of information about the similar devices, ultimately, we determined the overall design of the testing machine and with the help of PRO/E, the three-dimensional model of this machine was established. The structure is horizontal type with double axes, this structure is not only can load on both ends, reducing the overall size of machine, but also more convenient when install the test bearings. Secondly, based on momentum theory, blade element theory, momentum-blade element theory, axial force, radial force and overturning moment of spindle bearings, pitch bearings and yaw bearings were calculated. At last, the static strength and dynamic properties of testing machine key components of 3MW wind turbine bearing were analyzed to obtain the strength and stiffness check as well as the optimizing design of key components of bearing testing machine. The program of increase in wall thickness and add the trapezoidal ribs were compared, through contrast the advantages and disadvantages of two programs, and the strength was checked and satisfied with the demand of material strength. The former five orders natural frequencies and corresponding modes were obtained, which provides scientific basis for future design. At last, the structure of frame which meets the static analysis and modal analysis requirements were supplied.
引文
[1]包耳.风力发电技术发展现状.可再生能源,2004,5(2):12~15.
[2]熊礼俭.风力发电新技术与发电工程设计、运行、维护及标准规范实用手册.北京:中国科技文化出版社,2005.
[3] Armin schlereth.为风力发电机测试大型轴承.http://article.cechina..cn/wind/wind_turbines. html. 2009.
[4]李媛媛,叶亚飞.风力发电机用轴承.轴承,2004,12(2):48~49.
[5]陈雷,邢作霞,潘建等.大型风力发电机组技术发展趋势.可再生能源,2003,5(1):27~30.
[6] BTM Consult Aps-A part of Navigant Consulting. World Market Update 2010.
[7]李俊峰,蔡丰波,唐文倩等.风光无限-2011中国风电发展报告.北京:中国环境科学出版社2011.
[8]练松伟,徐玲玲,王金成等.JB/T10705-2007滚动轴承风力发电机轴承.北京:中华人民共和国国家发展和改革委员会,2007.
[9]陈龙,杜宏武,武建柯等.风力发电机用轴承简述.轴承,2008,7(12):48~49.
[10]刘忠明,段守敏,王长路.风力发电齿轮箱设计制造技术的发展与展望.机械传动,2006,1(6):1~6.
[11] Kim K. Design and development of a high-speed bearing test apparatus. Journal of Testing and Evaluation, 1998, 4(26): 301~305.
[12] Wakasa Tsuyoshi, Kazunari, Hayashi Yoshiyuki. Active vibration damping method for the wind turbine tower. Wind Turbine Generator, 2005, 3(6): 52~55.
[13] Joris Sones, Verna Thong, John Driesen. Modeling wind turbine generators for power system simulation. European wind energy conference, Paris, 2003: 1~8.
[14] Luis A Vega. Utility integrated wind turbine generators. Wind Technology Primer, 2005.
[15]冯琴,张先鸣.风电机组中的风电轴承.装备材料,2010,7(11):69~71.
[16]刘苏亚.轴承试验机及试验技术.轴承,2011,4(8):66~69.
[17] Mouhoub Mekhiehen. 1100F magnetic bearing for let turbine engines. Sym on Magnetic Bearing. Switzerland: Zurieh, 2000.
[18]张多利.大型轴承试验台研制及试验研究:(硕士学位论文).哈尔滨:哈尔滨工程大学,2008.
[19]华锐风电科技有限公司.风力发电机组中变桨轴承的测试方法及测试平台.中国,发明专利,200810119118.2008.
[20]洛阳轴研科技股份有限公司.一种测试风力发电变桨轴承的试验机.中国,发明专利,200810049626.2008.
[21]瓦房店轴承集团有限责任公司.一种风力发电机变桨轴承试验机.中国,发明专利,200720016686.2008.
[22]三一电气有限责任公司.风机偏航试验机构及风机整机试验台.中国,发明专利,200810204572.2009.
[23] Allet.A, Halle.S, Parasehivoiu. Numerical simulation of dynamic stall around an airfoil in durries motion. Journal of Solar Energy Engineering trans, 1999: 69~75.
[24]孙磊.大型风力发电机组风轮载荷的仿真计算与控制:(硕士学位论文).沈阳:沈阳工业大学,2009.
[25] McCoy, Malcolm.T, Griffin.D. An approach to the development of turbine loads in accordance with IEC1400-1 and IS0 2394. AIAA , 1999.
[26]曾杰.大型水平轴风力机载荷计算和强度分析的方法研究:(硕士学位论文).乌鲁木齐:新疆农业大学,2001.
[27] Burton, Sharpe, Jenkins. Wind Energy hand book. Oxford: Oxford university process, 2006. 59~65.
[28] Horiuchi, Kawahito.T. Torque and power limitations of variable speed wind turbines using pitch control and generator power control. Power engineering society summer meeting IEEE, New York, 2001: 638~646.
[29]李军向.大型风机叶片气动性能计算与结构设计研究:(博士学位论文).武汉:武汉理工大学,2001.
[30] Lanzafame, Messina. Design and performance of a double-pitch wind turbine with non-twisted blades. Renewable Energy, 2009, 34: 1413~1420.
[31] Johansen.J, Gauna.M. Design of a wind turbine rotor for maximum aerodynamic efficiency. Wind energy, 2009, 12: 261~273.
[32] Charley. Static and dynamic analysis of wind turbine blades using the finite element method. Computers and structures, 1993, 48(2): 273~290.
[33]李本立,宋宪耕,贺德馨等.风力机机结构动力学.北京:北京航天航空大学出版社,1999.24~27.
[34]周飞.水平轴风力发电机偏航轴承的性能分析与研究:(硕士学位论文).北京:华北电力大学,2008.
[35]才博.机械零部件设计中的非线性接触分析研究:(硕士学位论文).乌鲁木齐:新疆农业大学,2005.
[36]芮晓明,柳亦兵,马志勇.风力发电机组设计.北京:机械工业出版社,2010.
[37]姚兴佳,宋俊.风力发电机组原理与应用.北京:机械工业出版社,2011.
[38]孙江宏,黄小龙,罗坤.Pro/ENGINEER 2001版入门与提高.北京:清华大学出版社,2005.
[39]童秉枢,李学志,吴志军.机械CAD技术基础(第2版).北京:清华大学出版社,2004.29~47.
[40]张平.起重机回转支撑建模方法与有限元分析的研究:(硕士学位论文).长沙:中南林业科技大学,2008.
[41] William Maguire, Richard H Gallagher. Matrix Structural Analysis, Houston: John Wiley & Sons, 1979.
[42] Clough.R. The finite element method in plane stress analysis, Dallas: Am sue cave Engs, 1960. 345~378.
[43]陈正伟.大跨度机床横梁有限元分析与结构优化:(硕士学位论文).沈阳:东北大学,2008.
[44]邢树鑫.航空发动机轴间轴承试验机动静态特征分析:(硕士学位论文).哈尔滨:哈尔滨工业大学,2007.
[45]胡海峰.基于实体的有限元建模技术.机械,2003,30(5):78~80.
[46]姚士勇,常平平,柯仲英.基于Pro/E的ANSYS实体建模.制造业信息化,2007,4(7):52~53.
[47]易日.使用ANSYS6.1进行结构力学分析.北京:北京大学出版社,2002.
[48]廖伯瑜,周新民,尹志宏.现代机械动力学及其工程应用.北京:机械工业出版社,2003.248~249.
[49]段进,倪栋,王国业.ANSYS10.0结构分析从入门到精通.北京:兵器工业出版社,2006.
[50]张仁敬.基于ANSYS和Pro/E的WY22挖掘机工作装置的分析:(硕士学位论文).沈阳:东北大学,2008.
[2]熊礼俭.风力发电新技术与发电工程设计、运行、维护及标准规范实用手册.北京:中国科技文化出版社,2005.
[3] Armin schlereth.为风力发电机测试大型轴承.http://article.cechina..cn/wind/wind_turbines. html. 2009.
[4]李媛媛,叶亚飞.风力发电机用轴承.轴承,2004,12(2):48~49.
[5]陈雷,邢作霞,潘建等.大型风力发电机组技术发展趋势.可再生能源,2003,5(1):27~30.
[6] BTM Consult Aps-A part of Navigant Consulting. World Market Update 2010.
[7]李俊峰,蔡丰波,唐文倩等.风光无限-2011中国风电发展报告.北京:中国环境科学出版社2011.
[8]练松伟,徐玲玲,王金成等.JB/T10705-2007滚动轴承风力发电机轴承.北京:中华人民共和国国家发展和改革委员会,2007.
[9]陈龙,杜宏武,武建柯等.风力发电机用轴承简述.轴承,2008,7(12):48~49.
[10]刘忠明,段守敏,王长路.风力发电齿轮箱设计制造技术的发展与展望.机械传动,2006,1(6):1~6.
[11] Kim K. Design and development of a high-speed bearing test apparatus. Journal of Testing and Evaluation, 1998, 4(26): 301~305.
[12] Wakasa Tsuyoshi, Kazunari, Hayashi Yoshiyuki. Active vibration damping method for the wind turbine tower. Wind Turbine Generator, 2005, 3(6): 52~55.
[13] Joris Sones, Verna Thong, John Driesen. Modeling wind turbine generators for power system simulation. European wind energy conference, Paris, 2003: 1~8.
[14] Luis A Vega. Utility integrated wind turbine generators. Wind Technology Primer, 2005.
[15]冯琴,张先鸣.风电机组中的风电轴承.装备材料,2010,7(11):69~71.
[16]刘苏亚.轴承试验机及试验技术.轴承,2011,4(8):66~69.
[17] Mouhoub Mekhiehen. 1100F magnetic bearing for let turbine engines. Sym on Magnetic Bearing. Switzerland: Zurieh, 2000.
[18]张多利.大型轴承试验台研制及试验研究:(硕士学位论文).哈尔滨:哈尔滨工程大学,2008.
[19]华锐风电科技有限公司.风力发电机组中变桨轴承的测试方法及测试平台.中国,发明专利,200810119118.2008.
[20]洛阳轴研科技股份有限公司.一种测试风力发电变桨轴承的试验机.中国,发明专利,200810049626.2008.
[21]瓦房店轴承集团有限责任公司.一种风力发电机变桨轴承试验机.中国,发明专利,200720016686.2008.
[22]三一电气有限责任公司.风机偏航试验机构及风机整机试验台.中国,发明专利,200810204572.2009.
[23] Allet.A, Halle.S, Parasehivoiu. Numerical simulation of dynamic stall around an airfoil in durries motion. Journal of Solar Energy Engineering trans, 1999: 69~75.
[24]孙磊.大型风力发电机组风轮载荷的仿真计算与控制:(硕士学位论文).沈阳:沈阳工业大学,2009.
[25] McCoy, Malcolm.T, Griffin.D. An approach to the development of turbine loads in accordance with IEC1400-1 and IS0 2394. AIAA , 1999.
[26]曾杰.大型水平轴风力机载荷计算和强度分析的方法研究:(硕士学位论文).乌鲁木齐:新疆农业大学,2001.
[27] Burton, Sharpe, Jenkins. Wind Energy hand book. Oxford: Oxford university process, 2006. 59~65.
[28] Horiuchi, Kawahito.T. Torque and power limitations of variable speed wind turbines using pitch control and generator power control. Power engineering society summer meeting IEEE, New York, 2001: 638~646.
[29]李军向.大型风机叶片气动性能计算与结构设计研究:(博士学位论文).武汉:武汉理工大学,2001.
[30] Lanzafame, Messina. Design and performance of a double-pitch wind turbine with non-twisted blades. Renewable Energy, 2009, 34: 1413~1420.
[31] Johansen.J, Gauna.M. Design of a wind turbine rotor for maximum aerodynamic efficiency. Wind energy, 2009, 12: 261~273.
[32] Charley. Static and dynamic analysis of wind turbine blades using the finite element method. Computers and structures, 1993, 48(2): 273~290.
[33]李本立,宋宪耕,贺德馨等.风力机机结构动力学.北京:北京航天航空大学出版社,1999.24~27.
[34]周飞.水平轴风力发电机偏航轴承的性能分析与研究:(硕士学位论文).北京:华北电力大学,2008.
[35]才博.机械零部件设计中的非线性接触分析研究:(硕士学位论文).乌鲁木齐:新疆农业大学,2005.
[36]芮晓明,柳亦兵,马志勇.风力发电机组设计.北京:机械工业出版社,2010.
[37]姚兴佳,宋俊.风力发电机组原理与应用.北京:机械工业出版社,2011.
[38]孙江宏,黄小龙,罗坤.Pro/ENGINEER 2001版入门与提高.北京:清华大学出版社,2005.
[39]童秉枢,李学志,吴志军.机械CAD技术基础(第2版).北京:清华大学出版社,2004.29~47.
[40]张平.起重机回转支撑建模方法与有限元分析的研究:(硕士学位论文).长沙:中南林业科技大学,2008.
[41] William Maguire, Richard H Gallagher. Matrix Structural Analysis, Houston: John Wiley & Sons, 1979.
[42] Clough.R. The finite element method in plane stress analysis, Dallas: Am sue cave Engs, 1960. 345~378.
[43]陈正伟.大跨度机床横梁有限元分析与结构优化:(硕士学位论文).沈阳:东北大学,2008.
[44]邢树鑫.航空发动机轴间轴承试验机动静态特征分析:(硕士学位论文).哈尔滨:哈尔滨工业大学,2007.
[45]胡海峰.基于实体的有限元建模技术.机械,2003,30(5):78~80.
[46]姚士勇,常平平,柯仲英.基于Pro/E的ANSYS实体建模.制造业信息化,2007,4(7):52~53.
[47]易日.使用ANSYS6.1进行结构力学分析.北京:北京大学出版社,2002.
[48]廖伯瑜,周新民,尹志宏.现代机械动力学及其工程应用.北京:机械工业出版社,2003.248~249.
[49]段进,倪栋,王国业.ANSYS10.0结构分析从入门到精通.北京:兵器工业出版社,2006.
[50]张仁敬.基于ANSYS和Pro/E的WY22挖掘机工作装置的分析:(硕士学位论文).沈阳:东北大学,2008.