兆瓦级风电齿轮箱结构轻量化研究
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摘要
风能作为一种清洁的可再生能源,已引起了人们的高度重视,由此促成了风力发电产业的迅猛发展。风电齿轮箱结构复杂、传动比大,在高空塔架上作业且采用侧面支承,因此导致箱体刚性较差,故障率较高。风电齿轮箱的关键技术一直是制约风电产业快速发展的重要因素,由于风电机组单机容量的不断增大,在设计制造过程中需要考虑越来越多的因素。本文以兆瓦级风电齿轮箱为研究对象,在保证风电齿轮箱结构性能的前提下,综合应用各种结构优化方法对其进行轻量化研究,主要内容如下：
(1)风电齿轮箱静力学和动力学分析。根据风电齿轮箱组件的结构特点,在三维绘图软件SolidWorks中建立各组件的简化模型并进行总体装配,确定合理的有限元分析载荷状况和边界条件,导入CAE软件HyperWorks和Workbench中完成模型的几何清理和结构静力学分析及箱体整机模态分析,得到极限载荷工况下风电齿轮箱箱体和输入级行星架的位移场和应力场以及箱体的各阶固有频率和振型图。
(2)风电齿轮箱结构轻量化设计。对齿轮箱箱体进行了尺寸优化、形状优化和形貌优化；对输入级行星架进行了拓扑优化和尺寸优化。根据齿轮箱的设计要求,分别确定各种设计变量进行不同的优化设计。另外,出于优化设计的考虑,本文的结构优化设计都在三倍极限载荷下进行。
(3)基于支持向量机的结构优化。介绍了支持向量机的相关理论知识和算法领域新出现的果蝇优化算法,在此基础上编制MATLAB程序对齿轮箱箱体和输入级行星架尺寸优化中产生的样本数据进行建模和优化。优化结果表明,支持向量机有很强的泛化能力；果蝇优化算法寻优速度快,且能够很快找到全局最优解。
(4)优化前后模型的对比分析。基于齿轮箱的优化结果,对齿轮箱箱体和输入级行星架重新进行了分析,之后分别对齿轮箱箱体整机模型进行了静力分析和模态分析,并与原箱体结构进行了对比分析。除此之外,对优化后的齿轮箱后箱体和输入级行星架进行了平行度计算,并与初始模型平行度进行了对比分析。
综上所述,优化后的齿轮箱箱体和输入级行星架保证了原结构的性能,质量有较大幅度下降,共减重666.7kg(3.67%),达到了轻量化的效果。
As a kind of clean and renewable energy, wind power has attracted great attention of people, which leads to the rapid development of wind power generation industry. The structure of the wind power gearbox which works in the high-altitude tower is complex. Because of the use of side support and its large transmission ratio, the gearbox has poor rigidity and a high failure rate. The key technology of wind turbine gearbox has been an important factor in the rapid development of wind power industry. Especially, with the rapid increase of the wind turbine unit capacity, more and more factors need to be taken into consideration for the design and manufacture of large-scale wind turbine gearbox. In this paper, megawatt-level wind turbine gearbox is considered as the research object.Various structural optimization methods are applied to study the wind turbine gearbox when its original performance is guaranteed. The main contents are as follows:
(1) Static and dynamic analysis of wind turbine gearbox. Simplified models of the wind turbine gearbox components are established and then assembled in the3D graphics software SolidWorks according to the structural characteristics. In addition, the reasonable boundary conditions and loads for finite element analysis are determined. Then the simplified models are imported into CAE software HyperWorks and Workbench to finish the work of geometry cleanup, static analysis and modal analysis. Finally, analysis results including displacement field, stress field, natural frequencies and vibration modes of the gearbox and input stage planet carrier under limit load condition are obtained.
(2) Structural lightweight of wind turbine gearbox. Not only size optimization, shape optimization and topography optimization are applied to the wind turbine gearbox, but also topology optimization and size optimization are applied to the input stage planet carrier. According to the analysis results and design goal, different kinds of variables are determined to finish different optimization designs. In addition, for the consideration of optimization design, all structural optimizations are carried out under the limit load condition.
(3) Structural optimization based on support vector machine. Relevant theory knowledge about support vector machine and fruit fly optimization algorithm which is newborn in the field of optimization algorithm is introduced. Then, programme in MATLAB to model and optimize using the sample datas generated in size optimization of the gearbox and planet carrier. As the results show, support vector machine has a strong generalization ability; fruit fly optimization algorithm has a quick optimization speed and can quickly find the global optimal solution.
(4) Analysis and comparison between the original model and the optimized model. According to the structural optimization results, wind turbine gearbox and input stage planet carrier are remodeled and reanalyzed. Then static analysis and modal analysis which are compared with the original ones are carried out for wind turbine gearbox. In addition, calculation of parallelism values is applied to wind turbine gearbox and input stage planet carrier, and compare them with the original ones.
In summary, the optimized wind turbine gearbox and input stage planet carrier ensure the performance of the original structure. What's more, the total quality decreases substantially by3.67%, which is about666.7kg, achieving the goal of lightweight.
(1)风电齿轮箱静力学和动力学分析。根据风电齿轮箱组件的结构特点,在三维绘图软件SolidWorks中建立各组件的简化模型并进行总体装配,确定合理的有限元分析载荷状况和边界条件,导入CAE软件HyperWorks和Workbench中完成模型的几何清理和结构静力学分析及箱体整机模态分析,得到极限载荷工况下风电齿轮箱箱体和输入级行星架的位移场和应力场以及箱体的各阶固有频率和振型图。
(2)风电齿轮箱结构轻量化设计。对齿轮箱箱体进行了尺寸优化、形状优化和形貌优化；对输入级行星架进行了拓扑优化和尺寸优化。根据齿轮箱的设计要求,分别确定各种设计变量进行不同的优化设计。另外,出于优化设计的考虑,本文的结构优化设计都在三倍极限载荷下进行。
(3)基于支持向量机的结构优化。介绍了支持向量机的相关理论知识和算法领域新出现的果蝇优化算法,在此基础上编制MATLAB程序对齿轮箱箱体和输入级行星架尺寸优化中产生的样本数据进行建模和优化。优化结果表明,支持向量机有很强的泛化能力；果蝇优化算法寻优速度快,且能够很快找到全局最优解。
(4)优化前后模型的对比分析。基于齿轮箱的优化结果,对齿轮箱箱体和输入级行星架重新进行了分析,之后分别对齿轮箱箱体整机模型进行了静力分析和模态分析,并与原箱体结构进行了对比分析。除此之外,对优化后的齿轮箱后箱体和输入级行星架进行了平行度计算,并与初始模型平行度进行了对比分析。
综上所述,优化后的齿轮箱箱体和输入级行星架保证了原结构的性能,质量有较大幅度下降,共减重666.7kg(3.67%),达到了轻量化的效果。
As a kind of clean and renewable energy, wind power has attracted great attention of people, which leads to the rapid development of wind power generation industry. The structure of the wind power gearbox which works in the high-altitude tower is complex. Because of the use of side support and its large transmission ratio, the gearbox has poor rigidity and a high failure rate. The key technology of wind turbine gearbox has been an important factor in the rapid development of wind power industry. Especially, with the rapid increase of the wind turbine unit capacity, more and more factors need to be taken into consideration for the design and manufacture of large-scale wind turbine gearbox. In this paper, megawatt-level wind turbine gearbox is considered as the research object.Various structural optimization methods are applied to study the wind turbine gearbox when its original performance is guaranteed. The main contents are as follows:
(1) Static and dynamic analysis of wind turbine gearbox. Simplified models of the wind turbine gearbox components are established and then assembled in the3D graphics software SolidWorks according to the structural characteristics. In addition, the reasonable boundary conditions and loads for finite element analysis are determined. Then the simplified models are imported into CAE software HyperWorks and Workbench to finish the work of geometry cleanup, static analysis and modal analysis. Finally, analysis results including displacement field, stress field, natural frequencies and vibration modes of the gearbox and input stage planet carrier under limit load condition are obtained.
(2) Structural lightweight of wind turbine gearbox. Not only size optimization, shape optimization and topography optimization are applied to the wind turbine gearbox, but also topology optimization and size optimization are applied to the input stage planet carrier. According to the analysis results and design goal, different kinds of variables are determined to finish different optimization designs. In addition, for the consideration of optimization design, all structural optimizations are carried out under the limit load condition.
(3) Structural optimization based on support vector machine. Relevant theory knowledge about support vector machine and fruit fly optimization algorithm which is newborn in the field of optimization algorithm is introduced. Then, programme in MATLAB to model and optimize using the sample datas generated in size optimization of the gearbox and planet carrier. As the results show, support vector machine has a strong generalization ability; fruit fly optimization algorithm has a quick optimization speed and can quickly find the global optimal solution.
(4) Analysis and comparison between the original model and the optimized model. According to the structural optimization results, wind turbine gearbox and input stage planet carrier are remodeled and reanalyzed. Then static analysis and modal analysis which are compared with the original ones are carried out for wind turbine gearbox. In addition, calculation of parallelism values is applied to wind turbine gearbox and input stage planet carrier, and compare them with the original ones.
In summary, the optimized wind turbine gearbox and input stage planet carrier ensure the performance of the original structure. What's more, the total quality decreases substantially by3.67%, which is about666.7kg, achieving the goal of lightweight.
引文
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[2]赵琴.多兆瓦级风力发电机行星齿轮箱的研究和行星齿轮的有限元分析[D].乌鲁木齐：新疆农业大学,2009.
[3]闫凌宇.国内风电产业概况和存在问题的初步分析[J].电器工业,2008,(08)：12-14.
[4]ANSI/AGMA/AWEA 6006-A03, Standard for Design and Specification of Gearbox for Wind Turbine [S].2003,10.
[5]张立勇,王长路,刘法根.风力发电及风电齿轮箱概述[J].机械传动,2008,：32(6)：1-4.
[6]李俊峰,高虎.中国风电发展报告[M].北京：中国环境科学出版社,2007.
[7]许佳音,崔国敏,王刚.YB1502型变速器箱体的轻量化探索[J].工程机械,2011,42(10)：32-35.
[8]杨成云,林腾蛟,李润方.中心传动齿轮箱体有限元分析及结构优化设计[J].重型机械,2001,2：42-46.
[9]曹凤利,李国璋,傅建平.基于有限元的履带车辆变速箱体强度分析[J].机械工程师,2006,(7)：108-110.
[10]褚永康,文杜林,崔中,等.基于遗传算法的汽车变速箱轻量化设计[J].合肥工业大学学报,2011,34(10)：1461-1465.
[11]赵丽娟,刘宏梅,陈令国.ANSYS在矿用减速器箱体应力分析中的应用[J].矿业研究与开发,2007(2)：52-54.
[12]孙黎,王碧石,王春秀.大型风力发电机齿轮箱的有限元分析[J].华东电力,2008,36(7)：74-75.
[13]李树吉,陈雷,杨树人.风力机齿轮箱的优化设计[J].中国新能源期刊,2000,12.
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