Methods and devices for accessing a drive train of a wind turbine with elastic coupling, wind turbine and methods
11236730 · 2022-02-01
Assignee
Inventors
Cpc classification
F03D15/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D66/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D2066/003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F03D80/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2260/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D2300/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D3/58
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D3/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F16D15/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D15/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D3/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16D66/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Methods and devices for monitoring a drive train for a wind turbine utilize an elastic coupling. The drive train comprises a rotor shaft configured to be driven by a rotor about a main axis, a support structure including a bearing housing surrounding at least one bearing and supporting the rotor shaft for rotation about the main axis to constrain other movements of the rotor shaft. A gearbox input shaft and housing supports the gearbox input shaft for rotation while constraining other movements of the gearbox input shaft. The gearbox input shaft is coupled to the rotor shaft by an elastic coupling that includes a first coupling part rigidly connected with the rotor shaft, a second coupling part rigidly connected with the gearbox input shaft, and elastic elements positioned between the first and the second coupling part to provide a single joint between the rotor shaft and the gearbox input shaft.
Claims
1. A drive train for a wind turbine comprising: a rotor shaft configured to be driven by a rotor about a main axis; a support structure including a bearing housing surrounding at least one bearing and supporting the rotor shaft for rotation about the main axis, thereby constraining other movements of the rotor shaft; a gearbox input shaft and a gearbox housing supporting the gearbox input shaft for rotation about the main axis while constraining other movements of the gearbox input shaft; and an elastic coupling that couples the gearbox input shaft to the rotor shaft, the elastic coupling comprising a first coupling part rigidly connected with the rotor shaft, a second coupling part rigidly connected with the gearbox input shaft, and elastic elements positioned between the first and the second coupling part, thereby constituting a single joint between the rotor shaft and the gearbox input shaft, wherein the rotor shaft and the gearbox input shaft are mounted with a preset eccentricity of longitudinal main axes of the rotor shaft and the gearbox input shaft, such that the longitudinal axis of the rotor shaft and the longitudinal axis of the gearbox input shaft are mounted eccentrically to each other in order to minimize any eccentricity or offset resulting from weight and/or loads and/or torque during operation, wherein the elastic coupling comprises a sensor device to monitor a condition of the elastic coupling, wherein the sensor device is a rotational sensor device comprising rotational sensor targets and rotational sensor units, and wherein the first coupling part and the second coupling part of the elastic coupling each comprise a rotational sensor target being attached to a respective circumference of the first and second coupling part to determine a at least one of a rotational speed of the rotor shaft and/or the gearbox; a phase shift between the rotational position of the rotor shaft and the rotational position of the gearbox based on the output of the sensor; and a load torque of the elastic elements.
2. The drive train according to claim 1, wherein the rotational sensor targets are of an optical type, a magnetic type and/or physically marked.
3. The drive train according to claim 2, wherein at least one rotational sensor target of the rotational sensor targets is physically marked and toothed.
4. The drive train according to claim 1, wherein rotational sensor units corresponding to the rotational sensor targets are arranged in a coupling housing.
5. The drive train according to claim 1, wherein the sensor device is an axial sensor device and/or a radial sensor device and/or tangential sensor device.
6. The drive train according to claim 1, wherein the elastic elements are configured such that the elastic elements have a first stiffness in a first load direction and a second stiffness in a second load direction, the first stiffness being greater than the second stiffness, and the elastic elements are arranged such that a main load torque direction coincides with the first load direction.
7. The drive train according to claim 1, wherein the elastic elements are pre-stressed in a non-loaded condition in order to increase a torsional stiffness.
8. The drive train according to claim 1, wherein the rotor shaft comprises a wind turbine main shaft.
9. A drive train for a wind turbine comprising: a rotor shaft configured to be driven by a rotor about a main axis; a support structure including a bearing housing surrounding at least one bearing and supporting the rotor shaft for rotation about the main axis, thereby constraining other movements of the rotor shaft; a gearbox input shaft and a gearbox housing supporting the gearbox input shaft for rotation about the main axis while constraining other movements of the gearbox input shaft; and an elastic coupling that couples the gearbox input shaft to the rotor shaft, the elastic coupling comprising a first coupling part rigidly connected with the rotor shaft, a second coupling part rigidly connected with the gearbox input shaft, and elastic elements positioned between the first and the second coupling part, thereby constituting a single joint between the rotor shaft and the gearbox input shaft, wherein each of the elastic elements includes a chamber configured to be filled with a fluid and at least some of the chambers are hydraulically connected with each other, wherein the elastic coupling comprises a sensor device to monitor a condition of the elastic coupling, wherein the sensor device is a rotational sensor device comprising rotational sensor targets and rotational sensor units, and wherein the first coupling part and the second coupling part of the elastic coupling each comprise a rotational sensor target being attached to a respective circumference of the first and second coupling part to determine at least one of a rotational speed of the rotor shaft and/or the gearbox; a phase shift between the rotational position of the rotor shaft and the rotational position of the gearbox based on the output of the sensor; and a load torque of the elastic elements.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) Further features and advantages of the invention will ensue from the following description with reference to the accompanying drawings, wherein
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DETAILED DESCRIPTION OF EMBODIMENTS
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(19) There is further a sensor device SD in and/or on the elastic coupling 10 and/or the coupling housing 15, which is only one example for the various sensor devices described herein and in more detail below. The sensor signals acquired and/or processed by the sensor devices SD can be transmitted through wires/cables within the shaft(s) of the drive drain 1 towards the generator. This is advantageous for sensor devices, in particular sensor units of sensor devices SD which are attached to rotating parts, such as the elastic coupling 10. The sensor devices SD can further comprise sensor signal processing units SP. There is also a control logic CL and a programmable logic control PLC which can be configured to process signals from the sensor devices SD.
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(22) Furthermore, a rotational sensor signal processing unit (not shown) may be provided at the housing 15. The sensor signal processing unit may be configured to determine and/or process a phase shift between the rotational position of the rotor shaft 3 and the rotational position of the gearbox input shaft 6 based on the output of the rotational (speed) sensor device SDROT.
(23) The control logic CL shown in
(24) In an embodiment, the control logic CL can be further configured to determine whether stiffness properties of the elastic elements are in a required range based on (a) the phase shift and (b) a transmitted torque signal provided by the programmable logic controller PLC of the wind turbine representing the transmitted torque.
(25) In this embodiment, the rotational sensor targets ROTT1, ROTT2 on the first coupling part 11 and the second coupling part 12 of the elastic coupling 10 are configured as closed rings along the circumference. In another embodiment, the sensor targets ROTT1, ROTT2 on the first coupling part 11 and the second coupling part 12 of the elastic coupling are discontinuous along the circumference.
(26) A sensor signal processing unit (not shown) can be configured to determine the rotational speed of the rotor shaft 3 and/or the gearbox input shaft 6 and to provide the signal to the wind turbine PLC.
(27) The drive train 1, in particular the elastic coupling 10 can further comprise one or more proximity and/or distance sensor devices SDGAP which are configured to determine the gap/distance between the coupling housing 15 and the first coupling part 11 and/or the second coupling part 12. The output of such a distance sensor SDGAP can be taken into account for determining the coupling condition and/or generating the phase shift signal.
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(29) This allows to derive the amount of torque and the properties/condition/state of the elastic module EM. Each elastic module EM in the elastic coupling 10 may have a tangential sensor device SNT. The tangential sensor device SNT may also comprise a sensor unit and a sensor target. The tangential sensor device may be a distance sensor based on/using laser technology.
(30) The tangential sensor device SNT can also be configured to determine a distance and/or change of distance between the first coupling part 11 and the second coupling part 12 in the tangential direction.
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(32) Since the axial, radial and tangential sensor devices are attached to the rotating elastic coupling, the signals provided by these sensors can be transmitted via cable through the rotating shafts and picked up downstream of the drive train in a contactless manner of per commutator or slip rings etc.
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(34) The directions “radial”, “axial” and “tangential” are indicated in
(35) In an advantageous embodiment, the elastic coupling 10 comprises all the described sensor devices. The values, distances etc. determined/detected by the sensor devices can generally and advantageously be used to determine a condition of the elastic coupling 10. The values, distance etc. determined/detected by the sensor devices SA, SR, SNT, SDROT, SDGAP can be used in order to adapt or change the properties of the elastic coupling 10, in particular the properties of the elastic elements EM of the elastic coupling 10. Such a property can be the stiffness of the elastic elements in a specific direction, for example the dominant direction of stiffness or any other direction (as described herein). The adaption/maintenance/exchange of the elastic coupling 10 is advantageously be done in response to output signals provided by at least one or all of the sensor devices. The adaption/maintenance/exchange of the elastic elements may be performed automatically. An automatic adaption/maintenance may be performed by adapting a pressure in a hydraulic circuit to which one or more of the elastic elements are.
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(37) The circumferential direction CD is also the direction of the torque load. However, the torque load can have a first direction LDP or a second direction LDN which are opposite to each other. In the present context, a torque or load torque or load torque direction is represented and described rather by the rotational direction than by the vector representation, as the referral to the rotational directions is considered more intuitive.
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(43) This provides that a single elastic element EM can be used for both, opposite load torque direction, i.e. the positive torque direction LDP and the negative torque direction LDN. The elastic element is than only compressed or squeezed along the dominant axis or direction of stiffness regardless of the load torque direction. The number of required elastic elements EM can then be reduced to half the number of embodiments using pairs of modules.
(44) In an aspect, if the elastic elements use a chamber for fluid for adjusting the stiffness of the elastic elements, all the elastic elements can be hydraulically coupled with each other. It is not necessary to separate the hydraulic connection into one system for positive load torque and one system for negative load torque.
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(47) In still other words, any elastic element EM has a dominant axis of stiffness DA and a dominant direction of stiffness D1 lying in the dominant axis of stiffness DA. The dominant direction of stiffness D1 is advantageously a direction in which the elastic element EM is compressed. The stiffness of the elastic element EM is greater in the dominant direction of stiffness D1 than in any direction relative to the elastic element EM different from the dominant direction D1.
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(49) The elastic element EM shown in
(50) The elastic element EM can also be referred to as rubber hydraulic element. It can have a pitch cycle diameter of 2300 mm, a weight of 38 kg and provide a high torsional stiffness in the dominant direction. It further provides a low axial and lateral stiffness, i.e. in directions other than the dominant direction. The elastic element can operate with a hydraulic pressure of max. 600 bar. It can be hydraulically coupled with other elastic elements of a similar type through hoses or tubes (hydraulic circuit). The working pressure of these tubes or hoses can be 1040 bar, while the minimum burst pressure could be 2600 bar.
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(52) In an embodiment, a longitudinal axis A3 of the rotor shaft 3 and a longitudinal axis A6 of the gearbox input shaft 6 are then mounted/assembled with a predetermined and preset eccentricity EXC with respect to each other in order to minimize the offset/eccentricity resulting from, for example weight and/or other loads and/or other effects. Normally, it is most advantageous that the rotor shaft 3 and the gearbox input shaft 6 of a drive train 1 of a wind turbine are perfectly aligned and centered with respect to each other. Otherwise, any coupling and in particular an elastic coupling 10, more specifically the elastic elements EM of the elastic coupling 10, as described herein, can be constantly agitated/worked through during each rotation. This can substantially increase the wear of the elastic elements EM. According to the present embodiment, the rotor shaft 3 and the gearbox input shaft 6 are arranged with respect to each with a slight eccentricity in order to compensate any other effects that introduce an opposite eccentricity. If for example the coupling housing 15, the gearbox housing 8 and the generator 9 are all freely suspended from the bearing housing 5, this can introduce a slight eccentricity between the rotor shaft 3 and the gearbox input shaft 6 which results in an eccentricity in the elastic coupling 10, in particular an eccentricity of the first coupling part 11 with respect to the second coupling part 12. This and any other eccentricity can then be compensated, for example by the suspension of the bearing housing 5, in particular the suspension of the main bearing 4 in the bearing housing 5. The bearing housing 5 may be coupled to the main frame 16 of the nacelle by an annular (ring-shaped) flange (not shown). This flange can be used to create the eccentricity between the rotor shaft 3 and the gearbox input shaft 6. In particular, the center point of the bearing may be shifted during mounting/assembly. An advantageous direction is a preset eccentricity in a vertical direction V. It is also possible to create the preset eccentricity in any other directions, as for example the horizontal direction H. The preset eccentricity is advantageously in the range of less than 1 mm. The preset eccentricity provides that the elastic elements EM are not or less agitated during each rotation. Since the gearbox 7 (housing) and the generator 9 (housing) are suspended on the bearing housing 5, the weight of these components can introduce an eccentricity that is to be compensated by a predetermined and preset eccentricity in the opposite direction. Accordingly, an expected or determined eccentricity can be compensated by a slight preset and compensating (for example opposite) eccentricity introduced by a shift of the bearing housing 5. The preset eccentricity of the longitudinal main axes of the rotor shaft and the gearbox input shaft can be used to compensate and/or minimize any eccentricity or offset resulting from weight and/or loads and/or torque. The relevant torque could be the normal expected torque during operation of the wind turbine. In order to achieve the preset eccentricity the center point of the bearing housing may be slightly shifted. The center point of the bearing housing may be shifted vertically. This has an influence on the bending line such that in total, the undesired eccentricities are compensated by the preset eccentricity during mounting and/or assembling of the wind turbine/drive train.
(53) It should be noted that the aspects and embodiments are particularly synergetic. Monitoring of an elastic coupling of a drive train is important as the elastic elements of the elastic coupling can be subject to aging or wear. This requires a constant monitoring and, if any problems occur an adaption, maintenance or exchange of the elastic elements.
(54) Although the invention has been described hereinabove with reference to specific embodiments, it is not limited to these embodiments and no doubt further alternatives will occur to the skilled person that lie within the scope of the invention as claimed