风电增速器行星轮系动态性能分析与参数优化
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摘要
目前,风电装备正朝着大型化和高可靠性方向不断发展,对于风机设计和运行维护等方面提出了更高的要求。风机传动系统面临独特的动力学问题,同时风电装备在全寿命区间上的复杂随机载荷历程也使得风机传动系统的设计和计算有了与以往不同的特点。这些都使得风电装备动力学基础理论和动态性能分析具有非常深刻的意义。
本文以大功率风电增速齿轮箱的两级行星轮系为研究对象,以齿轮动力学的振动理论为基础,以数值仿真分析为手段,对两级行星轮系的动力学特性和振动行为进行了研究,并对齿轮箱的设计参数进行优化设计以达到减振降噪的目的。
首先,建立系统动力学模型和分析模型。根据齿轮系统自身的特点,采用集中质量法建立了两级行星轮系的弯—扭—轴耦合非线性动力学模型,在模型中综合考虑误差激励、时变啮合刚度激励和齿侧间隙等影响因素。在动力学模型的基础上建立了两级系统的非线性时变分析模型。
第二,分析系统的动力学特性：以固有特性计算理论为依据,分别对第一级、第二级和两级耦合行星轮系的固有频率进行了计算,并总结得到了各自的振动模式,在此基础上,研究了时变啮合刚度、行星架扭转刚度、太阳轮和行星轮的支撑刚度以及各轮质量对系统固有频率的影响。
第三,研究系统的振动行为：利用双参数威布尔分布模拟风电齿轮箱的外部变载激励,对两级行星轮系的非线性变参数微分方程组进行无量纲化处理,通过对无量纲化后的方程组求解得到系统各自由度振幅的位移响应和各扭转自由度上的相图曲线和庞加莱图。研究了输入转速和连接轴的扭转刚度对系统位移振幅的影响规律。
最后,以减振降噪为目标对系统进行优化设计：以系统加速度峰值最小为目标,以行星轮系能够正确传动和保证系统强度满足要求为约束条件,建立基于动力学的参数优化设计模型,并对其参数进行优化设计。从优化前后结果对比可知,系统最大加速度峰值得到降低,其他各构件加速度也保持在较低数值,系统体积得以减小,达到了减振降噪和系统体积轻量化的目的。
At present, the development of wind power equipment is moving in the direction of large-scale and high reliability, therefore, a higher demand for wind turbine design, operation and maintenance is raised. Wind turbine drive system faces with the unique dynamics problems, and the complex random load course of wind power equipment in the life-cycle interval also makes the design and calculation of the wind turbine drive system have different characteristics. All these make wind power equipment dynamics basic theory and dynamic performance analysis have a very profound meaning.
The study object of this paper is the two-stage planetary gear trains in the high-power wind power speed-up machine. The dynamic characteristics and vibration behavior of the two-stage planetary gear trains were studied based on the vibration theory of the gear dynamics and by means of the numerical simulation analysis. The design parameters of the gearbox were optimized in order to achieve the purpose of reducing vibration and noise.
First, the system dynamics model and analysis model were created. According to the own characteristics of the gear system, the bend-twist-axis coupled nonlinear dynamics model of two-stage planetary gear trains was established by use of the lumped mass method. The model was built in full consideration of the error incentive, the time-varying meshing stiffness excitation, backlash and other influencing factors. On the basis of the dynamics model, the nonlinear time-varying analysis model of two-stage planetary gear trains was established.
Second, the dynamic characteristic of the system was analyzed. Based on inherent characteristic computation theory, the natural frequency of the first-stage, the second-stage and two-stage coupled planetary gear trains were calculated and the respective vibration modes were summarized. Furthermore, how the parameters such as the time-varying meshing stiffness, the torsional stiffness of the planet carrier, the support stiffness of the sun gear and planetary gear and the quality of every gear have an influence on the natural frequency of the system was studied.
Third, the vibration behavior of the system was studied. The external variable load incentive of the wind turbine gearbox was simulated by use of two-parameter Weibull distribution. Nonlinear variable parameter differential equations of two-stage planetary gear trains were made into dimensionless ones. The dimensionless equations were solved to obtain the displacement amplitude response of every degree of freedom, the phase diagram curve and Poincare figure of every twist degree of freedom. The effect of the input speed and the torsional stiffness of the connection shaft on the amplitude of each degree of freedom was studied.
Finally, the design parameters of the system were optimized in order to reduce vibration and noise. Parameter optimization design model based on dynamics was established as the goal of system acceleration peak minimum. Ensuring the correct drive of the planetary gear trains and making the system strength meet the requirements are the constraint conditions. The parameters were optimized. The contrast of results before and after optimization shows that the maximum acceleration peak of the system has been reduced, the other accelerations are maintained at a lower value, and the system volume are also reduced. The purpose of reducing vibration and noise and making the volume lightweight was achieved.
本文以大功率风电增速齿轮箱的两级行星轮系为研究对象,以齿轮动力学的振动理论为基础,以数值仿真分析为手段,对两级行星轮系的动力学特性和振动行为进行了研究,并对齿轮箱的设计参数进行优化设计以达到减振降噪的目的。
首先,建立系统动力学模型和分析模型。根据齿轮系统自身的特点,采用集中质量法建立了两级行星轮系的弯—扭—轴耦合非线性动力学模型,在模型中综合考虑误差激励、时变啮合刚度激励和齿侧间隙等影响因素。在动力学模型的基础上建立了两级系统的非线性时变分析模型。
第二,分析系统的动力学特性：以固有特性计算理论为依据,分别对第一级、第二级和两级耦合行星轮系的固有频率进行了计算,并总结得到了各自的振动模式,在此基础上,研究了时变啮合刚度、行星架扭转刚度、太阳轮和行星轮的支撑刚度以及各轮质量对系统固有频率的影响。
第三,研究系统的振动行为：利用双参数威布尔分布模拟风电齿轮箱的外部变载激励,对两级行星轮系的非线性变参数微分方程组进行无量纲化处理,通过对无量纲化后的方程组求解得到系统各自由度振幅的位移响应和各扭转自由度上的相图曲线和庞加莱图。研究了输入转速和连接轴的扭转刚度对系统位移振幅的影响规律。
最后,以减振降噪为目标对系统进行优化设计：以系统加速度峰值最小为目标,以行星轮系能够正确传动和保证系统强度满足要求为约束条件,建立基于动力学的参数优化设计模型,并对其参数进行优化设计。从优化前后结果对比可知,系统最大加速度峰值得到降低,其他各构件加速度也保持在较低数值,系统体积得以减小,达到了减振降噪和系统体积轻量化的目的。
At present, the development of wind power equipment is moving in the direction of large-scale and high reliability, therefore, a higher demand for wind turbine design, operation and maintenance is raised. Wind turbine drive system faces with the unique dynamics problems, and the complex random load course of wind power equipment in the life-cycle interval also makes the design and calculation of the wind turbine drive system have different characteristics. All these make wind power equipment dynamics basic theory and dynamic performance analysis have a very profound meaning.
The study object of this paper is the two-stage planetary gear trains in the high-power wind power speed-up machine. The dynamic characteristics and vibration behavior of the two-stage planetary gear trains were studied based on the vibration theory of the gear dynamics and by means of the numerical simulation analysis. The design parameters of the gearbox were optimized in order to achieve the purpose of reducing vibration and noise.
First, the system dynamics model and analysis model were created. According to the own characteristics of the gear system, the bend-twist-axis coupled nonlinear dynamics model of two-stage planetary gear trains was established by use of the lumped mass method. The model was built in full consideration of the error incentive, the time-varying meshing stiffness excitation, backlash and other influencing factors. On the basis of the dynamics model, the nonlinear time-varying analysis model of two-stage planetary gear trains was established.
Second, the dynamic characteristic of the system was analyzed. Based on inherent characteristic computation theory, the natural frequency of the first-stage, the second-stage and two-stage coupled planetary gear trains were calculated and the respective vibration modes were summarized. Furthermore, how the parameters such as the time-varying meshing stiffness, the torsional stiffness of the planet carrier, the support stiffness of the sun gear and planetary gear and the quality of every gear have an influence on the natural frequency of the system was studied.
Third, the vibration behavior of the system was studied. The external variable load incentive of the wind turbine gearbox was simulated by use of two-parameter Weibull distribution. Nonlinear variable parameter differential equations of two-stage planetary gear trains were made into dimensionless ones. The dimensionless equations were solved to obtain the displacement amplitude response of every degree of freedom, the phase diagram curve and Poincare figure of every twist degree of freedom. The effect of the input speed and the torsional stiffness of the connection shaft on the amplitude of each degree of freedom was studied.
Finally, the design parameters of the system were optimized in order to reduce vibration and noise. Parameter optimization design model based on dynamics was established as the goal of system acceleration peak minimum. Ensuring the correct drive of the planetary gear trains and making the system strength meet the requirements are the constraint conditions. The parameters were optimized. The contrast of results before and after optimization shows that the maximum acceleration peak of the system has been reduced, the other accelerations are maintained at a lower value, and the system volume are also reduced. The purpose of reducing vibration and noise and making the volume lightweight was achieved.
引文
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[3]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[J].机械传动,2006,30(6)：1-6.
[4]吴丽媛,周振阳,韩溪.浅谈风电齿轮箱早期的故障形式[J].黑龙江科技信息,2011,(13)：4.
[5]路宏,王文婷.风力发电机组齿轮箱的结构研究及故障分析[J].内蒙固石油化工,2011,(22)：16-18.
[6]雷亚国,何正嘉等.行星齿轮箱故障诊断技术的研究进展[J].机械工程学报,2011,47(19)：59-67.
[7]Johan Ribrant, Lina Margareta Bertling. Survey of Failures in Wind Power Systems With Focus on Swedish Wind Power Plants During 1997-2005[J]. IEEE Transactions on Energy Conversion,2007,22(1):167-173.
[8]El-morsy Mohamed S,Abouel-seoud Shawki, Rabeih El-Adl. Gearbox Damage Diagnosis using Wavelet Transform Technique[J]. International Journal of Acoustics and Vibration,2011,16(4):173-179.
[9]董进朝.大型风电齿轮箱关键设计技术研究[D].郑州：郑州机械研究所,2007.
[10]张庆伟,张博等.风力发电机齿轮传动系统的动态优化设计[J].重庆大学学报,2010,33(3)：30-35.
[11]李庆梅,元军锋,宋晓美.风电齿轮箱系统扭转振动固有特性计算分析[J].设计研发,2010,(11)：46-49.
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