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Gearbox with Impeller for speed increasing

Gearbox with Impeller for speed increasing

Gearboxes have a wide range of applications, such as in wind turbines. Gearboxes are an important mechanical component that is widely used in wind turbines. Its main function is to transmit the power generated by the wind wheel under the action of the wind to the generator and make it get the corresponding speed.
Generally, the speed of the wind wheel is very low, which is far from the speed required by the generator to generate electricity. It must be achieved through the speed-increasing effect of the gear pair of the gearbox, so the gearbox is also called the speed-increasing box.

The gear box bears the force from the wind wheel and the reaction force generated during gear transmission, and must have sufficient rigidity to withstand the action of force and torque, prevent deformation and ensure transmission quality. The design of the gearbox housing should be carried out in accordance with the requirements of the wind turbine power transmission layout, processing and assembly conditions, and ease of inspection and maintenance. With the rapid development of the gearbox industry, more and more industries and different companies have used gearboxes, and more and more companies have developed and grown in the gearbox industry.
The gearbox is based on the modular design principle of the unit structure, which greatly reduces the types of parts and components, and is suitable for large-scale production and flexible selection. The spiral bevel gears and helical gears of the reducer are made of high-quality alloy steel by carburizing and quenching. The tooth surface hardness is as high as 60±2HRC, and the tooth surface grinding accuracy is as high as 5-6.

Gearbox with Impeller
The bearings of the transmission parts are all domestic well-known brand bearings or imported bearings, and the seals are skeleton oil seals; the structure of the suction box, the larger surface area of ​​the cabinet and the large fan; reduce the temperature rise and noise of the whole machine, and improve the reliability of operation , The transmission power increases. It can realize parallel shaft, right-angle shaft, vertical and horizontal general box. The input methods include motor connection flange and shaft input; the output shaft can be output at right angles or horizontally. Solid shaft and hollow shaft, flange type output shaft are available . The gearbox can meet the installation requirements of a narrow space, and it can also be supplied according to customer needs. Its volume is 1/2 smaller than that of the soft gear reducer, the weight is reduced by half, the service life is increased by 3 to 4 times, and the carrying capacity is increased by 8 to 10 times. Widely used in printing and packaging machinery, three-dimensional garage equipment, environmental protection machinery, conveying equipment, chemical equipment, metallurgical mining equipment, iron and steel power equipment, mixing equipment, road construction machinery, sugar industry, wind power generation, escalator and elevator drives, shipbuilding, light High-power, high-speed ratio, high-torque occasions such as industrial field, papermaking field, metallurgical industry, sewage treatment, building materials industry, lifting machinery, conveyor line, assembly line, etc. It has a good price-performance ratio and is conducive to the matching of localized equipment.

The gearbox has the following functions:
1. Accelerate and decelerate, which is often referred to as a variable speed gearbox.
2. Change the transmission direction. For example, we can use two sector gears to transmit the force vertically to the other rotating shaft.
3. Change the rotating torque. Under the same power condition, the faster the gear rotates, the smaller the torque on the shaft, and vice versa.
4. Clutch function: We can separate the engine from the load by separating the two originally meshed gears. Such as brake clutches and so on.
5. Distribution of power. For example, we can use one engine to drive multiple slave shafts through the main shaft of the gearbox, so as to realize the function of one engine driving multiple loads.

Gearbox with Impeller

design
Compared with other industrial gearboxes, since wind turbine gearboxes are installed in a narrow nacelle tens of meters or even more than a hundred meters above the ground, their volume and weight affect the nacelle, tower, foundation, wind load, installation and maintenance of the unit. Costs have an important impact, therefore, it is particularly important to reduce the size and weight. At the same time, due to inconvenient maintenance and high maintenance costs, the design life of the gearbox is usually required to be 20 years, and the requirements for reliability are also extremely harsh. Because size, weight and reliability are often an irreconcilable contradiction, the design and manufacture of wind power gearboxes are often caught in a dilemma. In the overall design stage, on the premise of meeting the requirements of reliability and working life, the transmission schemes should be compared and optimized with the goal of minimum size and weight; the structural design should meet the transmission power and space constraints as the premise, and try to consider the simple structure, Reliable operation and convenient maintenance; product quality should be ensured in every aspect of the manufacturing process; the gearbox operating status (bearing temperature, vibration, oil temperature, quality change, etc.) should be monitored in real time during operation and routine maintenance should be carried out according to specifications.
Since the linear speed of the blade tip cannot be too high, the rated input speed of the gearbox gradually decreases with the increase of the single machine capacity, and the rated speed of the unit above MW generally does not exceed 20r/min. On the other hand, the rated speed of the generator is generally 1500 or 1800r/min, so the speed ratio of the large-scale wind power speed-increasing gearbox is generally around 75-100. In order to reduce the volume of the gearbox, wind power gearboxes above 500kw usually use power split planetary transmission; common structures of 500kw~1000kw have two forms of 2-level parallel shaft + 1 level planet and 1 level parallel shaft + 2-level planetary transmission. ; Megawatt gearboxes mostly adopt a 2-stage parallel shaft +1-stage planetary transmission structure. Because the planetary transmission structure is relatively complicated, and the large-scale internal gear ring is difficult to process, and the cost is high, even if the 2-stage planetary transmission is adopted, the NW transmission form is the most common.

Gearbox with Impeller

use
1.Accelerate and decelerate, which is often referred to as a variable speed gearbox.
2. Change the transmission direction, for example, we can use two sector gears to transmit the force to the other rotating shaft vertically.
3. Change the rotating torque. Under the same power condition, the faster the speed of the gear, the smaller the torque on the shaft, and vice versa.
4. Clutch function: We can achieve the purpose of separating the engine from the load by separating the two originally meshed gears. For example, the brake clutch and so on.
5. Power distribution. For example, we can use one engine to drive multiple slave shafts through the main shaft of the gearbox, so as to realize the function of one engine to drive multiple loads.

Gearbox with Impeller for speed increasing. Its characteristics are simple in design and easy to install. It can be installed within 3 minutes. It is portable, energy-saving, and oxygen-enhancing. The effect is different from that of an impeller-type waterwheel. The water erupts upwards, causing the water in a certain area to be boiling, which improves the contact between the water and the air during the eruption process, forms the dissolved oxygen at the bottom of the water surface aeration, and increases the dissolved oxygen in the water body. Secondly, the water passes through the motor during the eruption process, so that the motor and the reduction gear box are cooled by the water. The motor will work for a long time without heating, to ensure that the motor will not burn out or increase the current when it works for a long time.

Gearbox with Impeller

Compared with other industrial gearboxes, since wind turbine gearboxes are installed in a narrow nacelle tens of meters or even more than a hundred meters above the ground, their volume and weight affect the nacelle, tower, foundation, wind load, installation and maintenance of the unit. Costs have an important impact, therefore, it is particularly important to reduce the size and weight. At the same time, due to inconvenient maintenance and high maintenance costs, the design life of the gearbox is usually required to be 20 years, and the requirements for reliability are also extremely harsh. Because size, weight and reliability are often an irreconcilable contradiction, the design and manufacture of wind power gearboxes are often caught in a dilemma. In the overall design stage, on the premise of meeting the requirements of reliability and working life, the transmission schemes should be compared and optimized with the goal of minimum size and weight; the structural design should meet the transmission power and space constraints as the premise, and try to consider the simple structure, Reliable operation and convenient maintenance; product quality should be ensured in every aspect of the manufacturing process; the gearbox operating status (bearing temperature, vibration, oil temperature, quality change, etc.) should be monitored in real time during operation and routine maintenance should be carried out according to specifications.

Gearbox with Impeller

Since the linear speed of the blade tip cannot be too high, the rated input speed of the gearbox gradually decreases with the increase of the single machine capacity, and the rated speed of the unit above MW generally does not exceed 20r/min. On the other hand, the rated speed of the generator is generally 1500 or 1800r/min, so the speed ratio of the large-scale wind power speed-increasing gearbox is generally around 75-100. In order to reduce the volume of the gearbox, wind power gearboxes above 500kw usually use power split planetary transmission; common structures of 500kw~1000kw have two forms of 2-level parallel shaft + 1 level planet and 1 level parallel shaft + 2-level planetary transmission. ; Megawatt gearboxes mostly adopt a 2-stage parallel shaft +1-stage planetary transmission structure. Because the planetary transmission structure is relatively complicated, and the large-scale internal gear ring is difficult to process, and the cost is high, even if the 2-stage planetary transmission is adopted, the NW transmission form is the most common.

Gearbox with Impeller

The external gears of wind power gearboxes generally adopt the carburizing quenching gear grinding process. The introduction of a large number of high-efficiency and high-precision CNC forming gear grinding machines has made the level of gear finishing abroad in China and foreign countries not too far behind, and there is no technical difficulty in reaching the level 5 precision stipulated by the 19073 and 6006 standards. However, there is still a gap between China and foreign advanced technologies in terms of heat treatment deformation control, effective layer depth control, tooth surface grinding and tempering control, and gear tooth shaping technology.

Gearbox with Impeller
Due to the large size of the ring gear of the wind power gearbox and the high machining accuracy requirements, the manufacturing technology of the ring gear in my country is far behind the international advanced level, which is mainly reflected in the processing of helical internal gears and the deformation control of heat treatment.
The machining accuracy of the box, planet carrier, input shaft and other structural parts has a very important influence on the meshing quality of the gear transmission and the life of the bearing. The quality of the assembly also determines the life and reliability of the wind power gearbox. . In terms of the processing and assembly accuracy of structural parts, my country recognizes that the equipment level is far behind the advanced level of foreign countries. In addition to advanced design technology and necessary manufacturing equipment support, the acquisition of high-quality and high-reliability wind power gearboxes is inseparable from strict quality control in every link of the manufacturing process. The 6006 standard provides strict and detailed regulations on the quality assurance of gearboxes.

Gearbox with Impeller

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