Research on Failure of Wind Turbine Gearbox and Recent Development of Its Design and Manufacturing Technologies

Abstract

Abstract:

Large-scale, high reliability and long service duration were already the development directions of wind power equipment which also presented a number of challenges on the design and manufacturing technologies of large wind gearbox. Following an introduction to some crucial technical problems of wind turbine gearbox running, the failure mechanism of key parts, and the latest research on advanced design and manufacturing of wind turbine gearbox were discussed in detail. The gaps of research and real applications between China and overseas were analyzed. Finally, the future trends of wind turbine gearbox design and manufacturing were also prospected.

Key words: wind turbine gearbox, failure, design and manufacturing technologies, review

摘要：

大型化、高可靠性、长服役周期已经成为当今世界风电装备发展的方向,这给大型风电装备的传动齿轮箱的设计制造技术带来了一系列的挑战。统计结果表明,影响风电齿轮传动系统服役的关键问题是关键机械零部件的失效故障。近年来各国在关键零部件损伤失效机理方面开展的基础研究工作,为风电齿轮箱系统的先进设计制造技术的研究与发展奠定了坚实的基础。必须紧扣风电齿轮箱设计制造技术的基础理论和发展方向,才能真正缩短我国与世界先进国家在风电传动系统的设计制造水平方面的显著技术差距。

关键词: 风电齿轮箱, 失效问题;设计制造技术;研究展望

CLC Number:

TM614
TH16

WANG Hui, LI Xiao-Long, WANG Gang, XIANG Dong, RONG Yi-Ming. Research on Failure of Wind Turbine Gearbox and Recent Development of Its Design and Manufacturing Technologies[J]. China Mechanical Engineering, 2013, 24(11): 1542-1549.

王辉, 李晓龙, 王罡, 向东, 融亦鸣. 大型风电齿轮箱的失效问题及其设计制造技术的国内外现状分析[J]. 中国机械工程, 2013, 24(11): 1542-1549.

References

[1]王文国，王永利.风电机低温问题及其解决方案[J].太阳能，2007(8): 38-39.
Wang Wenguo, Wang Yongli.Low Temperature Problem of Wind Turbine and Its Solutions[J]. Solar Engergy, 2007(8): 38-39.
[2]Crabtree C, Feng Y, Tavner P J. Detecting Incipient Gearbox Failure in Wind Turbines: A New Signal Analysis Method for On-line Condition Monitoring[C]//Proceedings of the Scientific Track of the European Wind Energy Conference. Warsaw, 2010: 154-156.
[3]Terrell E J, Needelman W M, Kyle J P. Tribological Challenges to the System[J].Wind Systems, 2010(3): 26-30.
[4]Energy Efficiency & Technology.Heading off Gearbox Failure[EB/OL].[2011-08-10].http://eetweb.com/wind/heading-off-gearbox-failure-0811/index.html.
[5]赵振宙，郑源，陈星莺.海上风电机组主要机械故障机理研究[J].水利水电技术，2009，40(9): 32-34.
Zhao Zhenzhou, Zheng Yuan, Chen Xingying. Research on Mechanism of Main Mechanical Faults of Offshore Wind Turbine[J].Water Resources and Hydropower Engineering, 2009，40(9): 32-34.
[6]张立勇.大型风电齿轮箱均载性能优化[D].北京：机械科学研究总院，2009.
[7]Musial W , Butterfield S, McNiff B. Improving Wind Turbine Gearbox Reliability Preprint[C]//2007 European Wind Energy Conference.Milan, 2007: 1-10.
[8]Sheng S S, McDade M, Errichello R.Wind Turbine Gearbox Failure Modes-a Brief[C]//ASME/STLE 2011 International Joint Tribology Conference. Los Angeles, 2011:1-26.
[9]Windpower Engineering. Wear-resistant Bearings for Wind Equipment[EB/OL].[2011-02-23]. http://www.windpowerengineering.com/design/mechanical/bearings/wear-resistant-bearings-for-wind-equipment/.
[10]赵玉良，徐鸿钧，姜永涛. 风电齿轮的微点蚀研究[J].能源工程，2010(4): 41-44.
Zhao Yuliang, Xu Hongjun, Jiang Yongtao. Research on Micropitting of Gear Fanks to Wind Turbine[J].Energy Engineering，2010(4): 41-44.
[11]Kapelevich A L. An Alternative Design for Speed Increasers[J].Wind Systems, 2010(4): 26-33.
[12]Veers P. Wind Turbine Design Standards: Influence on Reliability[C]//2nd Wind Turbine Reliability Workshop. Albuquerque, 2007：1-20.
[13]Ribrant J. Reliability Performance and Maintenance-A Survey of Failures in Wind Power Systems[D]. Stockholm：Royal Institute of Technology, 2006.
[14]LaPlante M. Carburizing Wind Turbine Gears[J]. Gear Solutions Magazine, 2009(5): 32-37.
[15]邢大志.风电齿轮箱内齿圈的强化途径[J].金属加工，2009(17): 14.
Xing Dazhi. Strengthen Methods of the Ring Gear in Wind Turbine Gearbox[J].Machinist Metal Forming，2009(17): 14.
[16]陈国民.关注风电齿轮技术推动企业技术进步[J].金属加工，2009(17): 8-10.
Chen Guomin.Concern on Wind Turbine Gear Technology, Promote Its Technological Progress[J].Machinist Metal Forming，2009(17): 8-10.
[17]Siebert H, Holm A P. Protecting Gears in Wind Power Applications[J]. Gear Solutions Magazine, 2009 (3):39-44.
[18]林腾蛟，沈亮，赵俊渝.风电增速箱输出级齿轮副疲劳寿命有限元分析[J].重庆大学学报，2012，35(1): 1-6.
Lin Tengjiao, Shen Lian, Zhao Junyu. Fatigue Life Finite Element Analysis of Output Gear Pair of Wind Turbine Speed-increase Gearbox[J].Journal of Chongqing University, 2012，35(1): 1-6.
[19]李明.风电增速箱斜齿轮齿向修形研究[D]. 大连：大连理工大学，2008.
[20]Schwingshandl F, Bodmer M, Fox G. MAAG DPPV-7-79 Gearbox—Advanced Solution of Modular Wind Turbine Drivetrain[EB/OL].[2013-02-01].http://www.timken.com/zh-cn/solutions/windenergy.
[21]Zhu Caichao, Xu Xiangyang, Lim T C, et al. Effect of Flexible Pin on the Synamic Behaviors of Wind Turbine Planetary Gear Drives[J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2013, 227(1): 74-86.
[22]Giger U, Arnaudov K. High Efficiency High Torque Gearbox For Multimegawatt Windturbines[J].The International Virtual Journal of Machines, Technologies and Materials, 2012(1):19-24.
[23]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.
Liu Zhongming, Duan Shoumin, Wang Changlu. Development and Prospect of the Wind Turbine Gearbox Design and Manufacturing Technology[J]. Journal of Mechanical Transmission, 2006，30(6): 1-6.
[24]任彦忠，牛海峰.国内风电设备质量现状和应对措施[J].发电设备，2012，26(2): 141-144.
Ren Yanzhong, Niu Haifeng.Quality Management Status of Domestic Wind Power Equipment and the Countermeasures[J]. Power Equipment，2012，26(2): 141-144.
[25]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.
Zhang Liyong, Wang Changlu, Liu Fagen. Summary on Development Status of Wind Power and Gearbox for Wind Turbine[J]. Journal of Mechanical Transmission, 2008，32(6): 1-4.