为预测风电齿轮箱各齿轮的接触疲劳寿命,以新疆达坂城风场某6 MW风电齿轮箱为研究对象,建立内外部激励作用的风电齿轮箱动力学模型,求解各斜齿轮啮合副的动态啮合力。考虑各齿轮的局部材料性能和残余应力,结合Dang Van多轴疲劳准则和S-N曲线,分析接触载荷作用下斜齿轮的疲劳损伤分布规律。进一步定位疲劳热点,抽取关键工况建立代理模型,计算齿轮箱20 a设计寿命内各齿轮的接触疲劳损伤和接触疲劳寿命。结果表明：斜齿轮外啮合副的啮入点和啮出点附近为疲劳热点区域,更易疲劳失效。太阳轮的接触疲劳损伤最大,高速级和低速级太阳轮的接触疲劳寿命分别为8和21 a;两级行星轮的接触疲劳损伤则较小,接触疲劳寿命都超过了30 a;内齿圈的接触疲劳损伤最小,其接触疲劳寿命很长。
Abstract
Wind turbine gearboxes are subjected to contact loads during operation, resulting in contact fatigue damage in the gears, which significantly affects their service life. To accurately predict the contact fatigue life of gears, this study takes a 6 MW wind turbine gearbox operating at Dabancheng Wind Farm, Xinjiang, as the research object. A gearbox dynamic model considering both internal and external excitations is established to calculate the dynamic meshing forces of each helical gear pair. The analysis incorporates local material properties and residual stresses in the gears. By applying the Dang Van multiaxial fatigue criterion combined with S-N curves, the fatigue damage distribution in the helical gears under contact loading is analyzed. Fatigue hotspots are identified, and critical operating conditions are extracted to develop a surrogate model, which quantifies the contact fatigue damage and estimates the contact fatigue life of each gear over a 20-year design period. The results indicate that the engage-in and recess points of external meshing pairs in helical gears are the primary fatigue hotspots, making them more susceptible to fatigue failure. Among all gears, the sun gears exhibit the most severe contact fatigue damage, with estimated contact fatigue life of 8 years for the high-speed sun gear and 21 years for the low-speed sun gear. Conversely, the planetary gears in both stages show relatively lower fatigue damage, with their contact fatigue life exceeding 30 years. The ring gear experiences the least fatigue damage, resulting in an exceptionally long service life.
关键词
齿轮 /
风电机组 /
疲劳损伤 /
多轴疲劳准则 /
接触载荷 /
关键工况
Key words
gears /
wind turbines /
fatigue damage /
multiaxial fatigue criterion /
contact loads /
key operating conditions
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基金
国家自然科学基金（52465015）; 新疆维吾尔自治区重点研发专项（2022B01017-3）; 新疆维吾尔自治区中央引导地方科技发展专项（ZYYD2024QY04）
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