针对风电机组齿轮箱在服役期间的可靠性问题,以2 MW风力机齿轮箱为研究对象,综合考虑齿轮时变啮合刚度与综合误差等内部激励,建立传动系统齿轮-轴-轴承动力学模型,获得恒定载荷下各齿轮副的动态啮合力。引用基于风场风速变化规律的威布尔随机风速作为系统外部激励,结合外部变动载荷与定载啮合力获得变载下各齿轮应力-时间历程。根据零部件主要失效模式,在传统应力-强度干涉模型基础上采用Gamma随机过程,结合齿轮材料的P-S-N（存活率-应力-寿命）曲线对零部件强度退化过程进行模拟。同时考虑到零件失效的相关性,建立系统主要失效模式的功能函数,构建混合Copula模型对零件层面与系统层面的失效相关性进行描述,经过多层嵌套获得齿轮箱系统的动态可靠度。结果表明：在风电机组服役前期时应主要考虑齿轮齿面接触疲劳失效,齿根弯曲疲劳失效主要发生在风力机服役中后期;根据系统可靠性曲线,考虑失效相关结果更符合实际工况。
Abstract
Aiming at the reliability of wind turbine gearbox in service, this article takes the 2 MW fan gearbox as the research object, comprehensively considers internal excitations such as time-varying meshing stiffness and comprehensive error of the gear, establishes a dynamic model of the transmission system gear shaft bearing, and obtains the dynamic meshing force of each gear pair under constant load. The Weibull random wind speed based on the variation law of wind speed in the wind field is cited as the external excitation of the system, and the stress time history of each gear under variable load is obtained by combining external variable load and fixed load meshing force. According to the main failure modes of parts, the strength degradation process of parts is simulated by using Gamma stochastic process based on the traditional stress strength interference model, combined with the P-S-N curve value of gear materials. Considering the correlation between component failures, a functional function of the main failure modes of the system is established, and a hybrid Copula model is constructed to describe the correlation between component level and system level failures. The dynamic reliability of the gearbox system is obtained through multi-layer nesting. The results indicate that the fatigue failure of the gear tooth surface should be mainly considered in the early stage of fan service, and the bending fatigue failure of the tooth root mainly occurs in the middle and late stages of service; According to the system reliability curve, considering the failure correlation, results are more consistent with the actual working conditions. This provides a reference for the reliability design of fan gearboxes.
关键词
风电机组 /
Copula /
齿轮 /
可靠性 /
强度退化 /
传动系统 /
失效相关
Key words
wind turbines /
Copula /
gear /
reliability /
strength degradation /
transmission system /
failure correlation
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 陈锐博, 秦大同, 刘长钊. 壳体柔性对风电齿轮箱-发电机集成系统动态特性影响[J]. 重庆大学学报, 2024, 47(3): 120-131.
CHEN R B, QIN D T, LIU C Z.Dynamic characteristics of a gearbox-generator integrated system with housing flexibility[J]. Journal of Chongqing University, 2024, 47(3): 120-131.
[2] 田和鑫. 风电齿轮箱的性能退化建模与可靠性分析[D]. 成都: 电子科技大学, 2021.
TIAN H X.Performance degradation modeling and reliability analysis of wind turbine gearbox[D]. Chengdu: Universityof Electronic Science and Technology of China, 2021.
[3] 郑朝朋. 2.5 MW风电齿轮箱可靠性分析[D]. 杭州: 浙江理工大学, 2015.
ZHENG C P.Reliability analysis of 2.5 MW wind turbine gearbox[D]. Hangzhou: Zhejiang Sci-Tech University, 2015.
[4] 周志刚, 秦大同, 杨军, 等. 随机风载作用下风力发电机齿轮传动系统疲劳寿命预测[J].太阳能学报, 2014, 35(7): 1183-1190.
ZHOU Z G, QIN D T, YANG J, et al.Fatigue life prediction of gear transmission system of wind turbine under stochastic wind load[J]. Acta energiae solaris sinica, 2014, 35(7): 1183-1190.
[5] 谢高敏, 章翔峰, 周建星, 等. 风电机组行星轮系柔性齿圈疲劳寿命研究[J]. 太阳能学报, 2023, 44(1): 179-187.
XIE G M, ZHANG X F, ZHOU J X, et al.Research on fatigue life of flexible gear ring of planetary gear train of wind turbine[J]. Acta energiae solaris sinica, 2023, 44(1): 179-187.
[6] LIU Y M, HU T, CHEN Y, et al.Dynamic fatigue analysis of high-speed trains gearbox using copula function[J]. Mathematical problems in engineering, 2022, 2022: 1088747.
[7] WANG H, ZHANG Y M, YANG Z.A reliability allocation method of cnc lathes based on copula failure correlation model[J]. Chinese journal of mechanical engineering, 2018, 31(1): 111.
[8] 邓智铭. 基于多性能退化的风力发电机增速齿轮箱可靠性评估[D]. 成都: 电子科技大学, 2021.
DENG Z M.Reliability evaluation of wind turbine gearbox based on multiple performance degradation[D]. Chengdu: University of Electronic Science and Technology of China, 2021.
[9] 周建星, 孙文磊, 曹莉, 等. 行星齿轮传动系统碰撞振动特性研究[J]. 西安交通大学学报, 2016, 50(3): 16-21.
ZHOU J X, SUN W L, CAO L, et al.Study on impact vibration characteristics of planetary gear transmission system[J]. Journal of Xi’an Jiaotong University, 2016, 50(3): 16-21.
[10] 郭新生. 风能利用技术[M]. 北京: 化学工业出版社, 2007.
GUO X S.Wind energy utilization technology[M]. Beijing: Chemical Industry Press, 2007.
[11] 易钰棠. 风电齿轮箱振动特性分析及结构拓扑优化[D]. 重庆: 重庆大学, 2021.
YI Y T.Vibration characteristics analysis and structural topology optimization of wind turbine gearbox[D]. Chongqing: Chongqing University, 2021.
[12] 林小燕, 魏静, 赖育彬, 等. 齿轮的剩余强度模型及其动态可靠度[J]. 哈尔滨工程大学学报, 2017, 38(9): 1476-1483.
LIN X Y, WEI J, LAI Y B, et al.Gear residual strength model and dynamic reliability[J]. Journal of Harbin Engineering University, 2017, 38(9): 1476-1483.
[13] BAI X C, ZHANG J Q, HE M, et al.Inference for stress-strength reliability of multi-state system with dependent stresses and strengths using improved generalized survival signature[J]. Journal of computational and applied mathematics, 2023, 420: 114809.
[14] 吴佳梁, 王广良, 魏振山. 风力机可靠性工程[M]. 北京: 化学工业出版社, 2010.
WU J L, WANG G L, WEI Z S.Wind turbine reliability engineering[M]. Beijing: Chemical Industry Press, 2010.
[15] 黄洪钟. 机械传动可靠性理论与应用[M]. 北京: 中国科学技术出版社, 1995.
HUANG H Z.Theory and application of mechanical transmission reliability[M]. Beijing: China Science and Technology Press, 1995.
[16] MENG D B, LV Z Y, YANG S Y, et al.A time-varying mechanical structure reliability analysis method based on performance degradation[J]. Structures, 2021, 34: 3247-3256.
[17] 裴帮, 李志远, 赵家栋, 等. 地铁齿轮的C-P-S-N曲线研究及其可靠性分析[J]. 机电工程, 2023, 40(4): 542-551.
PEI B, LI Z Y, ZHAO J D, et al.C-P-S-N curve of metro gear and its reliability analysis[J]. Journal of mechanical ＆ electrical engineering, 2023, 40(4): 542-551.
[18] 机械工程材料性能数据手册[M]机械工程材料性能数据手册[M]. 北京: 机械工业出版社, 1995.
Mechanical engineering material performance data manual[M]Mechanical engineering material performance data manual[M]. Beijing: Mechanical Engineering Press, 1995.
[19] 张震. 强度退化和失效相关的小样本齿轮可靠性研究[D]. 兰州: 兰州理工大学, 2021.
ZHANG Z.Study on reliability of small sample gear with strength degradation and failure correlation[D]. Lanzhou: Lanzhou University of Technology, 2021.
[20] 刘敬一, 庄新臣, 张玉刚, 等. 基于Copula函数的多功能机械系统竞争失效分析方法[J]. 西北工业大学学报, 2022, 40(4): 909-917.
LIU J Y, ZHUANG X C, ZHANG Y G, et al.Competing failure method for multi-performance mechanism systems based on Copula function[J]. Journal of Northwestern Polytechnical University, 2022, 40(4): 909-917.
[21] 冯钧, 刘伟, 谭龙, 等. 高维Copula函数的动态系统可靠性模型研究[J]. 机械强度, 2022, 44(1): 86-94.
FENG J, LIU W, TAN L, et al.Research on dynamic system reliability model of high dimensional copula function[J]. Journal of mechanical strength, 2022, 44(1): 86-94.
[22] 苏春, 汪千程. 基于改进多层级嵌套Copula方法的机电产品可靠性评估[J]. 东南大学学报(自然科学版), 2022, 52(5): 981-989.
SU C, WANG Q C.Reliability evaluation for electromechanical products based on improved multi-level nested Copula method[J]. Journal of Southeast University(natural science edition), 2022, 52(5): 981-989.
[23] 吕昊, 金雄程, 林录样. 基于Copula的车轮Gamma退化过程[J]. 东北大学学报(自然科学版), 2021, 42(4): 544-549, 566.
LYU H, JIN X C, LIN L Y.Wheel gamma degradation process based on copula function[J]. Journal of Northeast University (natural science), 2021, 42(4): 544-549, 566.
[24] 陈文华, 郑朝朋, 李奇志, 等. 基于Copula函数的2.5 MW风电齿轮箱齿轮可靠性分析[J]. 工程设计学报, 2015, 22(5): 425-430.
CHEN W H, ZHENG C P, LI Q Z, et al.Gear reliability analysis of 2.5 MW wind turbine gearbox based on Copula function[J]. Chinese journal of engineering design, 2015, 22(5): 425-430.
基金
新疆维吾尔自治区重点研发项目（2021B01003-1）; 新疆维吾尔自治区自然科学基金（2021D01C050）; 新疆维吾尔自治区重点研发项目（2022B01017-1）
PDF(2574 KB)
