超大功率多行星轮柔性销轴风电齿轮箱均载机理及构型研究

Multi-flex planetary gear pins type wind turbine gearbox is one of the key components for developing the super power wind driven generator. In view of the characteristics of multi floating component and the condition of variable wind load caused the problems in wind turbine gearbox with flexible pins, as the parameters matching rule of flexible pins is uncertainly, the load sharing mechanism of planetary gear is lacking and load sharing configurations method of gearbox is not good enough. Based on the research for the dynamic load distribution conditions of the multi-power flows and multi-float type gearbox under wind load, a novel idea, which integrates the excitation under complex wind load, the coordination of gear deformation, the definition of varying boundary definition, the prediction of load sharing and gearbox configurations, will be proposed to form the new principle and the new methods for the load sharing mechanism and gearbox configurations of the multi-flex planetary gear pins type wind turbine gearbox. The parameters matching method of multi-flex planetary gear pins will be explored to solve the problem about the gearbox protection caused by overload and realize adaptive adjustment when planetary gear load distribution is uneven. The load sharing law of multi-float components system under variable wind load conditions will be proposed to solve the problem of prediction under the condition of dynamically load for the wind turbine gearbox with multi-float components. A configuration method which integrate the power split flow and flexible pins will be proposed to solve the difficult to design the multi-float flexible pins type super power planetary gear system with the good load sharing performance. This proposed method is of great significance to guide the load sharing design of the super power wind turbine gearbox with the multi-flex planetary gear pins.

多行星轮柔性销轴风电齿轮箱是风力发电机向超大功率发展的关键零部件之一。针对目前柔性销轴风电齿轮箱中多浮动构件特征、变风载工况条件造成的柔性销轴参数匹配规律不明、行星轮均载机理缺乏、齿轮箱均载构型不理想问题，通过研究多功率流、多浮动构件风电齿轮箱在风力载荷下的行星齿轮动态载荷分配情况，形成集复杂风载激励、齿轮变形协调、时变边界确定、均载预估和均载构型于一体的多行星轮柔性销轴风电齿轮箱均载机理及构型理论体系。探索多行星轮柔性销轴齿轮系统销轴参数匹配方法，实现齿轮箱的过载保护与行星轮载荷不均时的自适应调节；揭示多浮动行星齿轮系统变风载工况下的均载规律，突破多浮动体风电齿轮箱动态均载预估难题；提出具有优良均载性能的多行星轮柔性销轴行星齿轮系统功率分流与柔性销轴融合构型方法，解决超大功率多行星轮柔性销轴行星齿轮系统均载设计难题。该研究对于指导超大功率多行星轮柔性销轴风电齿轮箱的均载设计具有重要意义。

针对超大功率多行星轮柔性销轴风电齿轮箱中多浮动构件耦合、外部变载荷条件，以及制造安装误差等影响因素造成的柔性销轴参数匹配规律不明、行星轮均载机理缺乏、行星齿轮箱均载构型不理想问题，本项目通过研究多自由度耦合动力学建模，柔性销轴参数匹配、行星轮动态均载演变规律、以及基于均载的构型和参数选择，形成一套系统的柔性销轴行星齿轮系统均载设计分析方法。通过项目执行，完成了以下研究工作：（1）提出了集外部变载荷、多浮动销轴、安装制造误差等综合因素下的齿轮-轴-轴承-箱体耦合多自由度非线性动力学模型，并完成了方程解耦及非线性特性研究；（2）完成了多行星轮柔性销轴齿轮系统销轴参数匹配及对动态载荷影响研究，分析行星轮柔性销轴参数与齿轮中心距、啮合相位、啮合刚度、外载荷之间的关联，探索出柔性销轴参数匹配规律及对齿轮动态载荷影响趋势；（3）进行了多浮动构件行星齿轮系统动态均载分析及验证研究，揭示出销轴刚度、啮合相位、啮合刚度、制造与装配误差、外载荷对多浮动齿轮系统行星轮载荷分配的影响规律，分析出多浮动构件行星齿轮系统结构参数及工作参数对行星轮均载的参数敏感度，实现了行星齿轮均载系统参数动态优化与匹配,并进行了试验验证；（4）提出了基于行星轮均载的多行星轮柔性销轴风电齿轮箱构型方法，在均载条件约束基础上，运用图论法表征行星齿轮机构的运动特征和拓扑构造，结合邻接矩阵法提出了新的行星齿轮系统构型方式，并运用模糊数学的方法对其所配置的构型进行具体的最优参数选择。该项目的研究对于指导超大功率多行星轮柔性销轴类风电齿轮箱的均载设计和均载分析具有重要的意义。