【作者】 张立勇；

【导师】 王长路； 刘忠明；

【作者基本信息】 机械科学研究总院 ， 机械设计及理论， 2009， 博士

【摘要】 随着能源短缺和环境污染问题的日益加剧,风能作为一种清洁的可再生能源,已被世界各国高度重视。近年来,虽然我国风电产业得到快速发展,但风电机组的总体设计制造水平与国际先进水平相比还有很大差距。风电齿轮箱是风电机组中最重要的部件之一。目前,我国已安装的风力发电机组,特别是大型风电机组的故障率居高不下,其中齿轮箱故障占了很大的比重。对大型风电齿轮箱进行系统的研究,降低风电机组中齿轮箱的故障率,提高风电机组的性能和可靠性对推动我国风电产业的发展有重要意义。大型风电齿轮箱中通常包括行星齿轮传动。均载性能直接决定着行星齿轮传动的可靠性等工作性能。本文主要对大型风电齿轮箱的均载性能及关键部件进行了研究,完成的主要工作和得出的结论包括以下几个方面。(1)建立了大型风电齿轮箱的静力学均载分析模型,进行了误差分析,得到了静力学载荷分布不均匀系数的计算方法和太阳轮浮动量。结果表明,系统的静力学载荷分布不均匀系数随各误差的增大而增大,内齿圈偏心误差对载荷分布不均匀系数的影响最大。在其他条件不变的情况下,载荷分布不均匀系数随太阳轮支撑刚度的增大而增大。(2)采用集中参数法建立了大型风电齿轮箱的动力学均载分析模型,得到了其运动微分方程。采用傅立叶法求解得到了系统的动载系数和动力学载荷分布不均匀系数。分析了各齿轮偏心误差和转速对动力学均载性能的影响。结果显示,太阳轮偏心误差对动力学均载性能的影响最大,其次是内齿圈,行星轮偏心误差的影响最小;系统的动力学载荷分布不均匀系数随转速的升高而增大。(3)以各级接触疲劳强度近似相等为目标函数,建立了大型风电齿轮箱传动参数优化设计模型,采用遗传算法完成了大型风电齿轮箱参数的优化设计。与传统设计方法相比较,本优化设计能够更好的实现系统的整体性能最优。(4)建立了行星架的刚度模糊可靠性模型,对行星架进行了刚度模糊可靠性优化设计,得到了行星架侧壁厚度的最优值。进一步通过有限元结构分析,优化了行星架侧壁连接板的结构。与初始设计的计算结果相比较,改进后结构的重量降低了32kg。优化前结构中最大位移为0.85mm,最大应力为211MPa;优化后的改进模型的最大位移为0.55mm,最大应力为91.70MPa。通过对行星架的优化及结构改进,很大程度上降低了结构的变形和应力,提高了行星架刚度,降低了行星架变形对轮齿啮合状态的影响。(5)在对某大型风电齿轮箱箱体受力进行系统分析的基础上,采用有限元法分析了各箱体组成部分在不同组合情况下的应力、变形情况。算例箱体的最大综合位移为1.169mm,出现在箱体背面区域,特别是左爪及轴承2受力的区域变形较大;最大应力为99.68MPa,满足设计要求。分析了整个箱体装配体的模态特性,结果表明其固有频率较高,前十阶固有频率在233.19Hz～526.8Hz范围内,其固有频率满足风电齿轮箱设计标准要求。(6)应用齿廓法线法推导出了插齿加工的渐开线直齿内齿圈的精确齿廓曲线方程,并通过Solidworks中的宏功能采用Visual Basic语言编程实现了内齿圈齿廓渐开线以及齿根过渡曲线的自动生成,建立了内齿圈的精确三维实体模型,研究了内齿圈的轮齿变形及齿根应力。结果表明,内齿圈的最大变形出现在齿顶的中间部位,而最大应力出现在受载齿的齿根部位;内齿圈的最大变形和齿根最大应力随着齿根过渡圆角半径的增大而减小。在螺栓孔及销孔不变的情况下,内齿圈的轮齿最大变形和齿根最大应力随轮缘厚度的增大而减小,螺栓孔及销孔对轮齿最大变形影响不大,但对齿根最大应力的影响比较显著。更多还原

【Abstract】 The energy shortage and environment pollution become increasingly serious. Wind power, as a clean and renewable energy, is paid great attention by the countries all over the world. In recently years, wind power of our country developed rapidly. But compared with the advanced level in the world, there’s still great disparity on the design and manufacturing technology of large scale wind turbine.Wind turbine gearbox is an important component in the wind turbine. At present, the failure rate of wind turbine, especially the large-scale wind turbine which has been installed in our country is high. And the failure of the gearbox takes a large proportion. Therefore, systematic study on the large scale wind turbine gearbox can help reduce the failure rate of the gearbox, improve the performance and reliability of wind turbine. This has important significance for promoting the development of the wind power industry in our country.The large scale wind turbine gearbox generally includes planetary transmission. The load sharing properties directly affect the operating performance, reliability and life of the planetary transmission. So the load sharing properties and the key parts in the large scale wind turbine gearbox are studied. The main work and conclusions are as following.1. The static load sharing analysis model of large scale wind turbine gearbox is built, and the transmission errors are analyzed. The calculation method of static load sharing coefficient and the floating quantity of sun gear is acquired. The results indicate that the load sharing coefficient increase when the eccentric errors increasing. And the gear ring eccentric error has the maxmum influence on the load sharing properties. When equal parameters, the load sharing coefficient increase as the sun gear supporting rigidity rising.2. The dynamic load sharing property model is built, and the motion differential equation is derived. The dynamic load coefficient and dynamic load sharing coefficient is got after solve the motion differential equation with Fourier method. The result indicate that the sun gear ecentric error has the most remarkable effect on dynamic load sharing coefficient, the secondly is gear ring eccentric error, the planet gear eccentric error has the smallest influence.3. The optimal design model of large scale wind turbine is built to reach the objection of contact-fatigue strength of different stage approximately equal. The optimization of transimission parameters is implemented through genetic algorithm program. Compared with traditional design, the optimal design provides a method to obtain integral reasonable transmission parameters of large scale wind turbine gearbox.4. The fuzzy reliability model of planetary carrier is built, and the fuzzy reliability optimal design for planet carrier is carried out. Through the optimum design, the optimum solution of side wall thickness is got. The structure of the connection board between the two side walls is further optimized by finite element method. Compared with the original design, the weight of planet carrier reduced 32Kg. The largest displacement on original design is 0.845mm, the largest stress is 211MPa. After the optimum design, the biggest displacement decrease to 0.55mm, and the maximum stress reduced to 91.7MPa. By the structural optimum design, the deformation and stress is reduced, the rigidity is enhanced, and the influence on tooth engagement state from the deforming of planet carrier is reduced.5. Analyzed the load that acted on the gearbox of large scale wind turbine. The stress and deformation of different assembled gearbox are studied by finite element method. The results indicate that the biggest complex displacement on gearbox reaches 1.17mm, and it appears on the back district of the gearbox, especially near the left supporting hole and the bearing two. The largest stress on the gearbox is 99.68MPa, satisfy the design requirement. Mode analysis of the entire assembled gearbox is carried out, the first ten step natural frequency and corresponding vibrate mode are got. The results indicate that the first ten step natural frequency range from 233.2Hz to 526.8Hz, the natural frequency is higher than the value specified by the standard.6. The profile equations of shaping gear ring are deduced out by profile normal line method. The involute and transition curves are automatically generated through the macro function in Solidworks. And the three-dimension model is built. Based on the three-dimension model, the deformation and dedendum stress is studied. The results indicate that the largest deformation appear on the middle region of the addendum, the position of largest stress appears at the dedendum region of loaded tooth. As the curvature radius of transition curve rising, both the largest deformation and the largest dedendum stress reduce. With unchanged hole structure, the largest displacement and largest stress reduce as the rim thickness increase. And the influence of hole structure to the displacement of the ring gear is small, but the hole structure has significant influence on the largest stress of ring gear.更多还原