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The design and analysis of a two stage reduction gearbox

The design and analysis of a two stage reduction gearbox

Gearboxes are an important mechanical component that is widely used in wind turbines.The design and analysis of a two stage reduction gearbox. Its main function is to transmit the power generated by the wind wheel under the action of the wind to the generator and get the corresponding speed.
Usually, the speed of the wind wheel is very low, which is far from the speed required by the generator to generate electricity. The design and analysis of a two stage reduction gearbox. It must be realized by the speed increasing action of the gear box gear pair. Therefore, the gear box is also called the speed increasing box.

The design and analysis of a two stage reduction gearbox

1. Introduction
The gearbox is subjected to the force from the wind wheel and the reaction force generated during the gear transmission. It must have sufficient rigidity to withstand the force and torque to prevent deformation and ensure the transmission quality. The design of the gearbox housing should be in accordance with the layout, processing and assembly conditions of the wind turbine power transmission, and easy inspection and maintenance.The design and analysis of a two stage reduction gearbox. With the rapid development of the gearbox industry, more and more industries and different enterprises have applied gearboxes, and more and more enterprises have grown stronger in the gearbox industry.

The design and analysis of a two stage reduction gearbox

According to the modular design principle of the unit structure, the gear box greatly reduces the types of parts and is suitable for large-scale production and flexible and variable selection. The design and analysis of a two stage reduction gearbox. The spiral bevel gear and the helical gear of the reducer are all carburized and quenched with high-quality alloy steel. The hardness of the tooth surface is up to 60±2HRC, and the precision of the tooth surface grinding is up to 5-6.
The design and analysis of a two stage reduction gearbox. The bearings of the transmission parts are all domestic famous brand bearings or imported bearings, and the seals are made of skeleton oil seals; the structure of the speaker body, the larger surface area of ​​the cabinet and the large fan; the temperature rise and noise of the whole machine are reduced, and the reliability of operation is improved. The transmission power is increased. Parallel axis, orthogonal axis, vertical and horizontal universal box can be realized. The input mode includes motor coupling flange and shaft input; the output shaft can be output at right angle or horizontal, and solid shaft and hollow shaft and flange are available.
Output shaft. The gearbox can meet the installation requirements of a small space, and can also be supplied according to customer requirements.The design and analysis of a two stage reduction gearbox. Its volume is 1/2 smaller than the soft tooth reducer, the weight is reduced by half, the service life is increased by 3~4 times, and the carrying capacity is increased by 8~10 times. Widely used in printing and packaging machinery, three-dimensional garage equipment, environmental protection machinery, transportation equipment, chemical equipment, metallurgical mining equipment, steel power equipment, mixing equipment, road construction machinery, sugar industry, wind power generation, escalator elevator drive, ship field, light High-power, high-speed ratio, high-torque applications such as industrial fields, papermaking, metallurgical industry, sewage treatment, building materials industry, lifting machinery, conveyor lines, and assembly lines. The design and analysis of a two stage reduction gearbox. It has a good cost performance and is conducive to the domestic equipment.

The design and analysis of a two stage reduction gearbox

2. Function
The gearbox has the following functions:
1. Accelerated deceleration is the variable speed gearbox that is often said.
2. Change the direction of the drive. For example, we use two sector gears to transmit the force vertically to the other.
3. Change the turning moment. Under the same power conditions, the faster the gear rotates, the smaller the torque the shaft receives, and vice versa.The design and analysis of a two stage reduction gearbox.
4. Clutch function: We can separate the engine from the load by separating the two originally meshed gears. Such as brake clutches.
5. Distribute power. For example, we can use one engine to drive multiple slave shafts through the gearbox main shaft, thus realizing the function of one engine to drive multiple loads.

The design and analysis of a two stage reduction gearbox

3. Design
Compared with other industrial gearboxes, because the wind turbine gearbox is installed in a small cabin that is several tens of meters or even more than one hundred meters high from the ground, its own volume and weight for the cabin, tower, foundation, unit wind load, installation and maintenance Costs and the like have an important impact, so it is important to reduce the size and weight.The design and analysis of a two stage reduction gearbox. 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 reliability requirements are extremely demanding. Because size and weight and reliability are often a pair of irreconcilable contradictions, the design and manufacture of wind turbine gearboxes often fall into a dilemma. The overall design stage should meet the requirements of reliability and working life, and compare and optimize the transmission scheme with the minimum volume and minimum weight as the target; the structural design should meet the transmission power and space constraints, and consider the structure as simple as possible. The design and analysis of a two stage reduction gearbox. Reliable operation and convenient maintenance; ensure product quality at every stage of the manufacturing process; in the operation, the gearbox operating status (bearing temperature, vibration, oil temperature and quality changes, etc.) should be monitored in real time and routinely maintained according to specifications.
Since the tip line speed cannot be too high, the rated input speed of the gearbox gradually decreases with the increase of the single unit capacity, and the rated speed of the unit above MW is generally not more than 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 wind power increasing gearbox is generally around 75~100. In order to reduce the volume of the gearbox, the wind power transmission box above 500kw usually adopts the power split planetary transmission; the common structure of 500kw~1000kw has two levels of parallel axis + 1 planet and 1 parallel shaft + 2 planetary transmission. The megawatt gearbox adopts a 2-stage parallel shaft +1 planetary transmission structure. Due to the relatively complicated planetary transmission structure and the difficulty in processing large internal ring gears, the cost is relatively high. Even with the 2-stage planetary transmission, the NW transmission is the most common.

4. Manufacturing technology
The external gear of the wind power gear box generally adopts a carburizing and quenching grinding process. The introduction of high-efficiency and high-precision CNC forming gear grinding machines has made our foreign gear finishing level not much different from that of foreign countries. There is no difficulty in achieving the 5-level precision technology specified by the 19073 standard and the 6006 standard. However, there are still gaps between China's advanced technology in heat treatment deformation control, effective layer depth control, tooth surface grinding tempering control, and gear tooth shaping technology.
Due to the large size of the ring gear of the wind turbine gearbox and the high processing precision, the manufacturing technology of the inner ring gear in China is quite different from the international advanced level, which is mainly reflected in the gear processing and heat treatment deformation control of the helical internal gear.
The design and analysis of a two stage reduction gearbox. The machining accuracy of the structural parts such as the box body, the planet carrier and the input shaft has a very important influence on the meshing quality of the gear transmission and the bearing life. The quality of the assembly also determines the length of the wind turbine gearbox and the reliability. . China has realized from the importance of the processing and assembly precision of structural parts that there is a certain gap between the level of equipment and the advanced level of foreign countries. The acquisition of high-quality, high-reliability wind turbine gearboxes, in addition to advanced design techniques and necessary manufacturing equipment support, is inseparable from the strict quality control of every step of the manufacturing process. The 6006 standard provides strict and detailed regulations on the quality assurance of the gearbox.

5. Lubrication
Commonly used gearbox lubrication methods include gear oil lubrication, semi-fluid grease lubrication, and solid lubricant lubrication. For better sealing, high speed, high load, good sealing performance can be lubricated with gear oil; for poor sealing, low-speed can be lubricated with semi-fluid grease; for oil-free or high-temperature applications Molybdenum sulfide superfine powder lubrication.
The lubrication system of the gearbox is very important for the normal operation of the gearbox. The large wind turbine gearbox must be equipped with a reliable forced lubrication system to inject the oil to the gear meshing area and bearings. In the cause of the failure of the gearbox, the lack of lubrication accounted for more than half. Lubricating oil temperature is related to component fatigue and overall system life.The design and analysis of a two stage reduction gearbox. Generally speaking, the maximum oil temperature of the gearbox should not exceed 80 °C during normal operation, and the temperature difference between different bearings should not exceed 15 °C. When the oil temperature is higher than 65 °C, the cooling system starts to work; when the oil temperature is lower than 10 °C, the oil should be heated to the predetermined temperature and then turned on.
In the summer, due to the long-term full state of the wind turbine, plus direct sunlight, the operating temperature of the oil rises above the set value; while in the cold winter in the northeast, the minimum temperature often reaches below 30 °C, lubrication. Lubricating oil in the pipeline is not smooth, gears and bearings are not fully lubricated, causing the gearbox to stop at high temperature, the tooth surface and bearing are worn out, and the low temperature will also increase the viscosity of the gearbox oil. When the oil pump starts, the load is heavy and the pump motor is overloaded. .
Gearbox lubricants have an optimum temperature range for operation. It is recommended to design a lubricant thermal management system for the gearbox lubrication system: when the temperature exceeds a certain value, the cooling system starts to work. When the temperature is lower than a certain value, the heating system starts to work. Always keep the temperature within the optimal range. In addition, improving the quality of lubricating oil is also an important aspect that must be considered in the lubrication system. Lubricant products must have excellent low temperature fluidity and high temperature stability, and research on high performance lubricating oil should be strengthened.

 

With Best Regards,
 
Lee ( Sales Department; Miss. )         
NER GROUP CO.,LIMITED    
Yantai Bonway Manufacturer Co., Ltd                        
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