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Speed-increase gearbox for wind power

This structure is mainly used for wind power gearbox with power of 2MW and below. A set of parallel gear unit is used to replace the planetary stage. It has high reliability, but large volume and weight.

key word:Heat exchange element


Product description

1. Wind power main gearbox structure

1.1. One stage of planetary gear unit and two stages of parallel gear units(See Fig. 1)

This structure is mainly used for wind power gearbox with power of 2MW and below. A set of parallel gear unit is used to replace the planetary stage. It has high reliability, but large volume and weight.

 

1.2. Two planetary stages and one parallel stage (See Fig. 2)

This structure is mainly used for gear boxes with power above 2.5MW. It has strong bearing capacity, small volume, light weight, small diameter but long transverse direction.

Some gearboxes below 2MW also adopt this structure.

 

1.3. Gearbox with spindle (See Fig. 3)

The spindle is mounted inside the gearbox

 

1.4. Compact gearbox (semi direct drive gearbox) (See Fig. 4)

It is usually also called semi direct drive gearbox. Semi direct drive takes into account the characteristics of direct drive and doubly fed fan motor. Compared with the doubly fed model, the transmission ratio of the semi direct drive gearbox is lower; Compared with the direct drive model, the generator speed of semi direct drive is higher. This characteristic determines that on the one hand, the semi direct drive can improve the reliability and service life of the gearbox. At the same time, compared with the direct drive generator, it can take into account the corresponding generator design and improve the design and manufacturing conditions of high-power direct drive generator.

Semi direct drive gearbox is a development trend. This semi direct drive gearbox is designed with the motor to reduce the weight of the gearbox, but the design requirements of the gearbox are improved.

 

2. Connection types between gearbox and spindle 

2.1. Shrink disc connection (See Fig. 5)

Generally used for models below 3MW

Unable to meet the needs of higher power models

 

2.2. Flange connection (See Fig. 6)

Available for higher power models

 

3. Fixing methods of gearbox  

3.1. Elastic support shaft connection (See Fig. 7)

3.2. Block connection (See Fig. 8)

 

 

4. Name plate of the gearbox

The name plate of l wind turbine gearbox generally contains the following information:

4.1. Model ------------ gearbox model;

4.2. Power ------------ operating power of gearbox under rated state, non fan (generator) power;

4.3. Speed ratio ----------- ratio of output speed and input speed of gearbox;

4.4. Input speed ---- input speed of gearbox planet carrier under rated state (blade speed);

4.5. Output speed ---- output speed of gearbox high-speed shaft under rated state (generator speed);

4.6. Weight ------------ generally refers to the weight of the gearbox before leaving the factory, excluding lubricating oil and possibly including the shrink disc (if the shrink disc is not included in the delivery, the displayed weight does not include the shrink disc);

4.7. Lubricating oil model --- recommended lubricating oil brand. Only lubricating oil approved by the design can be used; At the same time, it is also the brand of lubricating oil used in the factory test of gearbox. A series of cleaning must be carried out to replace other allowed lubricating oil;

4.8. Lubricating oil quantity ---- the designed lubricating oil quantity of the gearbox can meet the normal operation of the gearbox.

4.9. Serial number ---------- the unique number of the gearbox. The data of the manufacturing process of the gearbox can be found through the number;

4.10. Production date ----- manufacturing date of gearbox

See Fig. 9 as an example.

 

 

5. Detailed description of wind power gearbox structure

Here we take the assembly drawing of a 1.5MW gearbox as an example to discribe the gearbox structure: high speed stage, middle stage and low speed stage. See Fig.10 - Fig. 13

 

6. General bearing types of wind power gearbox:

6.1. Short cylindrical roller bearing nu

6.2. Short cylindrical roller bearing NJ

6.3. Single row full loaded cylindrical roller bearing NCF

6.4. Double row full loaded cylindrical roller bearing NNCF

6.5. Tapered roller bearing

6.6. Four point contact ball bearing

6.7. Deep groove ball bearing

6.8. Double row full loaded cylindrical roller bearing without outer ring

6.9. Spherical roller bearing

 

7. Lubrication oil

Lubricating oil is blended by base oil and different kinds of additives. According to the difference of base oil, lubricating oil can be divided into mineral oil and synthetic oil. Synthetic oil is a blend of synthetic base oil and additives.

Synthetic base oil: refers to the base oil generated by chemical methods with chemical raw materials and additives.

Mineral base oil: distillation, refining, dewaxing, hydrogenation and other production processes from crude oil.

Generally, due to the single and pure molecular structure of synthetic base oil, different molecular structures can be designed according to performance requirements. Therefore, the performance of synthetic lubricating oil is much better than mineral oil, mainly because the performance of synthetic base oil is much better than mineral base oil, but the price is also relatively high.

Common synthetic base oil for wind power gearbox: PAO (poly α Olefin), PAG (polyether), etc.

Additives are divided into:

Surface protection additives: anti-wear and extreme pressure, antifriction agent, anti micro pitting / anti pitting, anti-corrosion and anti rust, etc;

Fluid protection additives: anti oxygen passivator, anti foaming agent, etc;

Performance improvement additives: viscosity improver, pour point depressant, anti emulsification, etc

At present, the recommended lubricating oil brand mainly includes Mobilgear SHC XMP 320 and Optigear Synthetic X320

Note: it is not allowed to mix lubricating oils of different brands (including lubricating oils of different brands of the same brand). Lubricating oils of other brands can be added only after the residual oil inside the gearbox is cleaned.

 

8. External accessories

In addition to mechanical parts, the wind power gearbox also has some external accessories, such as electrical accessories, which support the good operation of the gearbox with its own functions. The common external accessories of wind power gearbox are listed below. Different gearbox may have some differences.

8.1. Lubrication cooling system

8.2. Mechanical pump

8.3. Differential pressure switch

8.4. Pressure sensor / pressure switch / pressure gauge

8.5. Junction box

8.6. Heater

8.7. Temperature sensor

8.8. Liquid level alarm

8.9. Liquid level gauge

8.10. Air cleaner

8.11. Cable

 

9. Gearbox model and technical data (from one MFG)

Gearbox model and technical data
Type   Rated input power (KW) Input speed (r/min) Ratio  Output speed (r/min)
600KW 645 26.8 56.6 1516.88
850KW 940 24 71.382 1713
1000KW 1100 21.5 83.701 1800
1250KW 1350 21.1/22.4 53.476/49.996 1128.3/1119.9
1500KW 1650 17.3/18/19 104/100/94.74 1799.2/1800/1800
1663 17.4 100.837 1754.6
1700 17.35 8.647 150
2000KW 2160 18 1700 94.696
2205 15 117.66 1764.9
2235 15.35 118.52 1810
2160 15.4 77.87 1200
2283 15 76.9 1154
2500KW 2760 14.2 84.5 1200
2750 13.97/14.3 85.89/83.91 1200
2760 14.2 84.5 1200
2929 13.9 84.75 1178
3000KW 3300 14.3 84.4 1200
3550 14.5 25.34 367
3600KW 4114 14 84.3 1180
5000KW 5800 11.4 106.8 1218