CN117365851B - Assembly system and assembly method for main shaft and gear box of wind generating set - Google Patents

Abstract

The present disclosure provides a pairing system and a pairing method for a main shaft and a gearbox of a wind turbine generator set. The pairing system includes a base, a position adjustment device, a monitoring module and a control module. The base is used to support the main shaft and the gearbox; the position adjustment device is arranged on the base, and is used to adjust the relative position of the gearbox and the main shaft; the monitoring module is used to monitor the position parameters of the gearbox and the main shaft; the control module can receive the monitoring result of the monitoring module, and send an adjustment signal to the position adjustment device according to the monitoring result. The position adjustment device can adjust the position of the gearbox according to the above-mentioned position parameters, so that the gearbox and the main shaft are aligned and matched, thereby realizing the automation of the pairing of the main shaft and the gearbox and reducing labor costs.

Description

A pairing system and a pairing method for a main shaft and a gearbox of a wind turbine generator set

Technical Field

The present invention belongs to the technical field of wind power generation, and in particular relates to a pairing system and a pairing method for a main shaft and a gear box of a wind power generator set.

Background Art

The current wind turbine generator sets mainly include doubly-fed wind turbine generator sets, direct-drive wind turbine generator sets and semi-direct-drive wind turbine generator sets.

At present, most of the double-fed wind turbine generator sets still use manual cranes to realize the transmission chain pairing process. For example, the gearbox and the main shaft are paired by manual cranes. Therefore, the transmission chain is completely dependent on the experience of the operator during pairing, and the pairing results vary from person to person. For industrial and commercial wind turbine generator sets, this greatly reduces the production efficiency. In wind turbine generator sets, batch production is often carried out, and the process cannot be dependent on the operator, which causes serious waste of resources and increases the cost of the unit assembly process.

Summary of the invention

The main purpose of the present disclosure is to provide a main shaft and gear box assembly system and assembly method to improve the assembly efficiency of a wind turbine generator set.

In view of the above-mentioned invention objectives, the present disclosure provides the following technical solutions:

In one aspect of the present disclosure, a main shaft and gearbox assembly system for a wind turbine generator set is provided, the assembly system comprising a base, a position adjustment device, a monitoring module and a control module, the base is used to support the main shaft and the gearbox; the position adjustment device is arranged on the base, and is used to adjust the relative position of the gearbox and the main shaft; the monitoring module is used to monitor the position parameters of the gearbox and the main shaft; the control module can receive the monitoring result of the monitoring module, and send an adjustment signal to the position adjustment device according to the monitoring result, so that the gearbox and the main shaft are aligned and matched. In this way, through the assembly system, the main shaft and the gearbox can be automatically assembled, reducing the labor cost in the assembly process.

According to an exemplary embodiment of the present disclosure, the position adjustment device includes a first position adjustment unit, a second position adjustment unit, a horizontal angle adjustment unit and a fourth position adjustment unit, wherein the first position adjustment unit is arranged on the base to adjust the position of the gear box on a horizontal first axis; the second position adjustment unit is arranged on the first position adjustment unit to adjust the position of the gear box on a horizontal second axis; the horizontal angle adjustment unit is arranged on the second position adjustment unit to adjust the angle of the gear box relative to the main shaft in a horizontal plane; the fourth position adjustment unit is arranged on the horizontal angle adjustment unit to adjust the height and/or horizontal inclination of the gear box, and the gear box is supported on the fourth position adjustment unit, wherein the horizontal first axis and the horizontal second axis are perpendicular to each other.

According to another exemplary embodiment of the present disclosure, the horizontal angle adjustment unit includes a matching stationary part and a rotating part, the stationary part is connected to the second position adjustment unit, the rotating part can rotate around a vertical axis relative to the stationary part, and the gear box is connected to the rotating part.

Optionally, the stationary part and the rotating part are coaxial to form a rotating component. As an example, the rotating component in the present disclosure is a bearing, for example but not limited to, the bearing is a rolling bearing; the horizontal angle adjustment unit also includes a servo motor, and the servo motor is fixedly connected to the rotating part.

Specifically, the fourth position adjustment unit includes two first driving members arranged at one end of the gear box close to the main shaft, and the two first driving members are symmetrically arranged on both sides of the gear box shell along the horizontal second axis direction; and/or, the fourth position adjustment unit includes a second driving member arranged at one end of the gear box away from the main shaft, and the second driving member is supported at the bottom of the shell and is located below the central axis of the shell.

According to another exemplary embodiment of the present disclosure, the base includes a main shaft support portion and a gear box support portion, wherein the first position adjustment unit is disposed on the gear box support portion, and the main shaft is supported on the main shaft support portion.

Optionally, the first position adjustment unit and/or the second position adjustment unit comprises a telescopic assembly or a screw assembly connected to the gear box support portion; and/or the first driving member and/or the second driving member comprises a telescopic assembly or a screw assembly.

Furthermore, the monitoring module includes a signal generator and a signal receiver, the signal generator is capable of sending a signal and being received by the signal receiver; the gear box includes a mating part, the mating part is assembled with the main shaft, the signal generator is arranged on one of the main shaft and the mating part, and the signal receiver is arranged on the other of the main shaft and the mating part so as to be able to measure the relative position of the mating part and the main shaft.

According to another exemplary embodiment of the present disclosure, the monitoring module further comprises a parts scanner for scanning a geometric center axis of a mating part of the main shaft and/or the gear box, and capable of transmitting the scanning result to the control module.

Optionally, the monitoring module further includes a displacement sensor, which is disposed at the mating portion and is used to measure the distance between the end face of the spindle and the end face of the mating portion.

Specifically, the signal generator is a laser generator, the signal receiver is a laser receiver, and the part scanner is a three-dimensional part scanner.

In another aspect, the present disclosure provides a method for assembling a main shaft and a gearbox for a wind turbine generator set, wherein the method uses the assembly system as described above, and the method comprises the following steps:

Get the position parameters of the spindle and gearbox respectively;

Determining position adjustment information of the gear box relative to the main shaft according to position parameters of the main shaft and the gear box;

The position adjustment information is sent to the position adjustment device to drive the gear box to move relative to the main shaft until the main shaft and the gear box are docked and assembled.

Optionally, the step of respectively acquiring position parameters of the main shaft and the gear box comprises determining the positional relationship between the main shaft and the central axis of the gear box.

Specifically, the step of sending the position adjustment information to the position adjustment device to drive the gear box to move relative to the main shaft includes:

An angle parameter of the position adjustment information in a horizontal plane is determined, and the angle parameter is sent to a position adjustment device to drive the gear box to rotate an angle around a vertical axis.

Optionally, the pairing method further comprises: after the gearbox rotates around the vertical axis by an angle, determining the horizontal angle deviation between the gearbox and the main shaft, and determining the measured position difference between the gearbox and the main shaft in the vertical direction, determining the adjustment information of the gearbox in the vertical direction according to the angle deviation and the measured position difference, and adjusting the position of the gearbox in the vertical direction. Furthermore, the step of sending the position adjustment information to the position adjustment device to drive the gearbox to move relative to the main shaft also comprises:

Determine a first adjustment distance of the position adjustment information on the horizontal second axis, and send the first adjustment distance to the position adjustment device to drive the gear box to move the first adjustment distance on the horizontal second axis; and/or,

Determine a second adjustment distance of the position adjustment information on the vertical axis, and send the second adjustment distance to the position adjustment device to drive the gear box to move the second adjustment distance on the vertical axis, or drive the gear box to adjust the horizontal inclination angle.

Optionally, the step of sending the position adjustment information to the position adjustment device to drive the gear box to move relative to the main shaft further includes:

A third adjustment distance of the position adjustment information on the horizontal first axis is determined, and the third adjustment distance is sent to the position adjustment device to drive the gear box to move the third adjustment distance on the horizontal first axis.

Specifically, during the movement of the gear box on the horizontal first axis, the speed change rate of the gear box is determined, and when the speed change rate exceeds a preset threshold, the gear box is moved in the reverse direction.

The main shaft and gearbox pairing system and pairing method for a wind turbine generator set provided in the present disclosure have at least the following beneficial effects: the pairing system includes a monitoring module, a control module and a position adjustment device, the monitoring module is used to monitor the position parameters of the gearbox and the main shaft, the control module can send the above position parameters to the position adjustment device, and the position adjustment device can adjust the position of the gearbox according to the above position parameters, thereby realizing the automation of the pairing of the main shaft and the gearbox and reducing labor costs.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other objects and advantages of the present disclosure will become more apparent through the following description of the embodiments in conjunction with the accompanying drawings, in which:

FIG. 1 is a structural diagram of a main shaft and gearbox assembly system provided by an exemplary embodiment of the present disclosure.

FIG. 2 is a front view of the main shaft and gearbox assembly system in FIG. 1 .

FIG. 3 is a structural diagram of the gear box position adjustment device in FIG. 1 .

FIG. 4 is a flow chart of a method for pairing a main shaft and a gearbox according to an exemplary embodiment of the present disclosure.

FIG. 5 is a flow chart of a method for pairing a main shaft and a gearbox according to another exemplary embodiment of the present disclosure.

Description of reference numerals:

2. Spindle;

3. Position adjustment device; 4. Monitoring module;

5. Control module; 6. Gear box;

8. Matching portion; 11. First supporting unit;

12. A second supporting unit; 13. A rotary bearing;

14. Gear box support; 31. Bottom support;

32. Middle support; 33. Top support;

34. Second driving member; 35. First driving member;

36. Rotating assembly; 37. First guide rail;

38. Second guide rail; 41. Signal generator;

42. Signal receiver; 43. Parts scanner;

44. Displacement sensor.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. However, it should not be understood that the implementation of the present disclosure is limited to the embodiments set forth herein. The same reference numerals in the figures represent the same or similar structures, and thus their detailed description will be omitted.

The present invention provides a main shaft and gearbox pairing system for a wind turbine generator set. The pairing system can be applied to the key process of main shaft and gearbox pairing in a doubly fed generator set, and is particularly suitable for wind turbine generator sets with a small dimensional margin between the main shaft and the gearbox and large size and weight.

The present invention provides a main shaft and gear box pairing system for a wind turbine generator set, which is used in the wind turbine generator set to improve the pairing efficiency of the main shaft and the gear box and reduce the manual pairing cost.

Referring to Fig. 1 to Fig. 3, an embodiment of the main shaft and gearbox assembly system for a wind turbine generator set provided by the present disclosure includes: a base, a position adjustment device 3, a monitoring module 4 and a control module 5, wherein the base is used to support the main shaft 2 and the gearbox 6, and the position adjustment device 3 is used to drive the gearbox 6 to move relative to the main shaft 2, so as to achieve the alignment of the main shaft 2 and the gearbox 6. The monitoring module 4 is used to monitor the relative position parameter information between the gearbox 6 and the main shaft 2, and can transmit the monitoring result to the control module 5, the control module 5 can receive the monitoring result, and can determine the adjustment information according to the monitoring result, and send the adjustment information to the position adjustment device 3, so as to control the position adjustment device 3 to drive the gearbox 6 to move, and achieve docking with the main shaft 2, so as to improve the assembly efficiency of the main shaft 2 and the gearbox 6, and reduce the manual assembly cost of the main shaft 2 and the gearbox 6.

A working process of the pairing system provided in the above embodiment may include: before pairing, the monitoring module automatically measures the axial position of the matching part of the gear box (to be connected to the main shaft), for example but not limited to, the matching part can be a hollow shaft of the planetary carrier, and the controller determines the adjustment information of the gear box relative to the main shaft based on the measured axial position, and sends the adjustment information to the position adjustment device, the position adjustment device 3 adjusts the relative horizontal position and distance between the gear box 6 and the main shaft 2, and then monitors the real-time position of the main shaft and the gear box in real time through the monitoring module 4, the controller determines the relative position and adjustment information of the main shaft and the gear box based on the real-time position, until the main shaft 2 and the gear box 6 are adjusted to coincide with the axial line, and finally the pairing is completed.

It can be seen from the above working process that the pairing device provided in the embodiment of the present application can effectively avoid uncontrollable factors caused by manual use of a lifting crane, which can not only play a safe and efficient role, but also achieve the purpose of reducing costs, thereby realizing the automatic pairing of the wind turbine main shaft and the gearbox.

In this embodiment, the base includes a main shaft support portion and a gear box support portion 14, wherein the main shaft support portion is used to support the main shaft 2, and the gear box support portion 14 is used to support the gear box 6. The main shaft support portion includes a pair of support units arranged at intervals along the extension direction of the main shaft 2, and the main shaft 2 is rotatably arranged on the main shaft support portion through a support bearing, but the present invention is not limited thereto. Continuing to refer to FIG. 1, the pair of support units are respectively a first support unit 11 and a second support unit 12, and the second support unit 12 is arranged close to the gear box 6.

This embodiment is described by taking the main shaft support part and the gear box support part 14 as independent components, but the present invention is not limited thereto. The main shaft support part and the gear box support part 14 may also be an integrated structural part.

The gearbox 6 is supported on the position adjustment device 3, which includes a horizontal displacement adjustment unit, a horizontal angle adjustment unit and a fourth position adjustment unit. The horizontal displacement adjustment unit is used to adjust the displacement of the gearbox 6 in the horizontal plane, and the horizontal angle adjustment unit is used to adjust the angle of the gearbox 6 relative to the main shaft 2 in the horizontal plane. The horizontal displacement adjustment unit includes a first position adjustment unit and a second position adjustment unit. The first position adjustment unit is arranged on the base to adjust the position of the gearbox 6 on the horizontal first axis. The second position adjustment unit is arranged on the first position adjustment unit to adjust the position of the gearbox 6 on the horizontal second axis. The horizontal angle adjustment unit is arranged on the second position adjustment unit to adjust the angle of the gearbox 6 relative to the main shaft 2 in the horizontal plane. The fourth position adjustment unit is arranged on the horizontal angle adjustment unit to adjust the height and/or horizontal inclination of the gearbox 6. The gearbox 6 is supported on the fourth position adjustment unit, wherein the horizontal first axis and the horizontal second axis are perpendicular to each other.

In this embodiment, the first position adjustment unit, the second position adjustment unit, the horizontal angle adjustment unit and the fourth position adjustment unit are arranged vertically in sequence from bottom to top.

Referring to the drawings, the first position adjustment unit includes a bottom support 31 and a corresponding driving portion. The bottom support 31 is movably disposed on the base along a horizontal first axis. For example but not limited to, in this embodiment, the bottom support 31 is movably disposed on the gear box support portion 14 .

Specifically, the corresponding driving part can be arranged in the gear box support part 14 to drive the bottom support 31 to move. As an example, the driving part that drives the bottom support 31 to move includes a servo motor and a screw assembly, or a telescopic assembly, but is not limited to this.

In order to improve the movement accuracy of the bottom support 31, the first position adjustment unit further includes a first guide rail 37. One of the gear box support portion 14 and the bottom support 31 is provided with the first guide rail 37, and the other is provided with a guide groove matching the first guide rail 37. In this embodiment, the first guide rail 37 is provided at the top of the gear box support portion 14, and the first guide rail 37 extends along a horizontal first axis, and the horizontal first axis is parallel to the Y direction, but is not limited thereto.

The second position adjustment unit may include an intermediate support 32 and a corresponding driving unit, wherein the intermediate support 32 is movably disposed above the bottom support 31 along the horizontal second axis, and the driving unit may be disposed in the intermediate support 32 to drive the intermediate support 32 to move relative to the bottom support 31. In addition, the driving unit may also be disposed in the bottom support 31, but is not limited thereto. As an example, similarly, the driving unit that drives the intermediate support 32 to move may include a servo motor and a screw assembly, or a telescopic assembly, but is not limited thereto.

In order to improve the movement accuracy of the intermediate support 32, the second position adjustment unit may include a second guide rail 38. Specifically, one of the bottom support 31 and the intermediate support 32 is provided with the second guide rail 38, and the other is provided with a guide groove matching the second guide rail 38, and the second guide rail 38 extends along the horizontal second axis direction, and the horizontal second axis is parallel to the X direction, but not limited thereto, so that the intermediate support 32 can move along the second guide rail 38. In this embodiment, the second guide rail 38 is provided at the top of the bottom support 31, but not limited thereto.

In Figure 2, the horizontal first axis can extend in the left-right direction, and the Y direction can be defined to extend horizontally to the right. The horizontal second axis can extend in the direction perpendicular to the paper, and the X direction can be defined to extend outward perpendicular to the paper. The vertical axis can extend in the up-down direction, and the Z direction can be defined to extend longitudinally upward, thereby determining the coordinate system.

Continuing to refer to the drawings, the horizontal angle adjustment unit includes matching stationary parts and rotating parts. The stationary part is connected to the second position adjustment unit. For example but not limited to, the stationary part can be fixed on the top of the intermediate support 32, and the rotating part can be sleeved on the outer periphery of the stationary part and rotate relative to the stationary part around the vertical axis. The gear box 6 is connected to the rotating part to be able to drive the rotating part to rotate and drive the gear box 6 to rotate around the vertical axis at the same time, so as to be able to adjust the angle of the gear box 6 relative to the main shaft 2 in the horizontal plane.

Optionally, the stationary member and the rotating member are coaxial to form a rotating assembly 36, and the horizontal angle adjustment unit further includes a servo motor, which is fixedly connected to the rotating member. As an example, the rotating assembly 36 can be a bearing, for example but not limited to, the bearing is a rolling bearing, but not limited thereto.

Considering that the gear box is often provided with an elastic support on the side of the gear box close to the main shaft when supporting, in one embodiment of the present application, the fourth position adjustment unit preferably includes a top support 33 and two first driving members 35 provided at one end of the gear box 6 close to the main shaft 2, and the two first driving members 35 are symmetrically provided on both sides of the housing of the gear box 6 along the horizontal second axis direction. The two first driving members 35 are correspondingly provided at the positions of the elastic support, effectively utilizing the structure of the gear box itself, thereby simplifying the structure of the position adjustment device.

Optionally, the top support 33 is rotatably disposed on the rotating assembly 36 along the vertical axis, so that the top support 33 is driven to rotate in the horizontal plane by the rotation of the rotating assembly 36, thereby driving the gear box 6 to rotate in the horizontal plane. The two first driving members 35 are disposed at one end of the top support 33 close to the main shaft 2, but the present invention is not limited thereto.

The fourth position adjustment unit also includes a second drive member 34 arranged at the end of the gear box 6 away from the main shaft 2. The second drive member 34 is supported at the bottom of the shell and is located below the central axis of the shell. The second drive member 34 is arranged at the end of the top support 33 away from the main shaft 2.

Optionally, the fourth position adjustment unit includes a second driving member 34 and two first driving members 35, and the first driving member 35 and the second driving member 34 can respectively push or pull the gear box 6 in the vertical direction. In the initial state, the central axis of the gear box 6 can be set horizontally, and when the second driving member 34 and the two first driving members 35 are respectively extended to the same length, or respectively retracted to the same length, the central axis of the gear box 6 can be kept horizontal, so that the horizontal height of the gear box 6 can be changed.

In addition, when the two first driving members 35 extend to a first length, the second driving member 34 extends to a second length, and the first length is less than or greater than the second length, the central axis of the gear box 6 is inclined with respect to the horizontal plane. As an example, the second driving member 34 is a telescopic assembly or a screw assembly, but is not limited thereto.

Referring to Figure 2, a specific embodiment of the position adjustment device provided by the present application is as follows: in order to drive the gear box 6 to move along the Y direction, the bottom support 31 is connected to the gear box support part 14 through a screw assembly, and the screw assembly can be used as a driving part of the bottom support 31. The screw assembly can extend along the Y direction to drive the bottom support 31 to move relative to the gear box support part 14 through the extension and contraction of the screw assembly.

Similarly, a screw assembly is provided between the bottom support 31 and the middle support 32 as a driving part of the middle support 32 , and the screw assembly can extend along the X direction to drive the middle support 32 to move along the X direction relative to the bottom support 31 through the extension and retraction of the screw assembly.

A rotating assembly 36 is further provided between the middle support 32 and the top support 33, and the rotating assembly 36 can drive the top support 33 to rotate around the vertical axis relative to the middle support 32. As an example, in this embodiment, the rotating assembly 36 can be a rolling bearing, the inner ring of which is connected to one of the middle support 32 and the top support 33, and the outer ring of which is connected to the other of the middle support 32 and the top support 33, but the present invention is not limited thereto.

The projection of the top support 33 perpendicular to the X direction is substantially L-shaped, and one side of the L-shaped top support 33 substantially extends along the Y direction, and the other side substantially extends along the Z direction.

Further, still referring to FIG. 1 , the projection of the top support 33 perpendicular to the Y direction is roughly U-shaped, the opening of the U-shaped top support 33 faces the Z direction, and the matching portion 8 in the gear box 6 is arranged in the U-shaped opening of the top support 33 .

The two first driving members 35 are respectively arranged on a pair of side edges of the U-shaped opening. The first driving member 35 is arranged at one end of the gear box 6 having the matching portion 8. The two first driving members 35 are symmetrically arranged on both sides of the bottom shell of the gear box 6 along the horizontal second axis direction.

As an example, the gearbox support 14, the bottom support 31, the middle support 32, the rotating assembly 36, the top support 33, and the first driving member and the second driving member are arranged in sequence from bottom to top, but the present invention is not limited thereto.

As an example, the position adjustment device 3 is divided into multiple layers of adjustment mechanisms. From bottom to top, the bottom layer is the Y-direction adjustment mechanism, that is, a group of servo motor-controlled ball screws arranged on the gear box support part 14 are used to accurately control the position of the bottom support 31 in the Y direction; the upper layer is the X-direction adjustment mechanism, which is controlled by a group of servo motor-controlled ball screws to accurately control the position of the middle support 32 in the X direction; the upper layer is the Z-direction rotation mechanism, which realizes the rotation of the gear box 6 around the Z axis by controlling a pair of rolling bearings by a servo motor; the top layer is a hydraulic mechanism for Z-direction displacement and X-direction rotation composed of three hydraulic jacks (i.e., the fourth position adjustment unit), which can adjust the overall height of the gear box 6 (i.e., move up and down along the Z direction), and can also adjust the front and rear height of the gear box 6 separately (i.e., rotate around the X direction to adjust the horizontal inclination angle). The above-mentioned position adjustment device 3 can meet the required degrees of freedom of the gear box 6 during assembly, and improve the accuracy of the position adjustment of the gear box 6 to the spindle 2 during the assembly process.

2, an exemplary embodiment of the present disclosure, the monitoring module 4 includes a signal generator 41 and a signal receiver 42, the signal generator 41 can send a signal and be received by the signal receiver 42, the signal generator 41 is arranged on one of the main shaft 2 and the matching part 8 of the gear box 6, and the signal receiver 42 is arranged on the other of the matching part 8 of the main shaft 2 and the gear box 6, so as to be able to measure the relative position of the matching part 8 and the main shaft 2. In this way, the spatial position of the main shaft 2 and the gear box 6 can be determined by the cooperation of the signal generator 41 and the signal receiver 42.

Optionally, the signal generator 41 may be a laser generator, but is not limited thereto. In this embodiment, the signal generator 41 and the signal receiver 42 form a laser alignment instrument. As an example, one of the signal generator 41 and the signal receiver 42 is disposed at the shaft end of the main shaft 2 facing the gear box 6. The other is disposed in the inner hole of the gear box planet carrier to determine the relative position of the main shaft and the gear box planet carrier in space, but is not limited thereto.

Taking into account the large size of the gearbox and main shaft used in the wind turbine generator system, it is necessary to consider not only the overall position requirements of the gearbox and the main shaft during the position adjustment process, but also the position requirements of the mating parts of the gearbox and the main shaft. Therefore, further, referring to Figure 2, in a pairing device provided in a preferred embodiment of the present application, the monitoring module 4 also includes a part scanner 43, which is used to scan the geometric center axis of the mating part 8 of the main shaft 2 and/or the gearbox 6, and can transmit the scanning results to the control module 5, so that the control module 5 can control the movement of the gearbox 6 according to the monitoring results.

In this embodiment, the shaft end of the main shaft 2 facing the gear box 6 and the inner hole of the planet carrier of the gear box 6 are three-dimensionally scanned by the part scanner 43, and the geometric center obtained by calculating the scanning result is sent to the control module 5 to determine the central axis of the main shaft 2 and the inner hole of the planet carrier of the gear box 6. As an example, the part scanner 43 is a three-dimensional part scanner, but it is not limited to this.

At this time, combined with the central axis determined by the scanner, the geometric center of the main shaft 2 is set as the fixed coordinate system X0Y0Z0 in the control module 5. This coordinate system is used as the reference for adjusting the gear box 6 during the assembly process. The geometric center of the inner hole of the planetary carrier of the gear box 6 is set as the adjustment coordinate system X1Y1Z1.

Through the two major coordinate systems determined in the above scheme, the control module 5 calculates the difference between the adjustment coordinate system X1Y1Z1 and the fixed coordinate system X0Y0Z0 through the relative position determined by the above scheme, and the difference is used as the adjustment value required for the adjustment coordinate system X1Y1Z1. At this time, adjusting the relative position of the main shaft 2 and the gear box 6 is to adjust the relative position of the two coordinate systems.

At the beginning of pairing, first adjust the angle in the Z direction, that is, adjust the angle of the gear box 6 through the rolling bearing (rotating component 36), and adjust the angle in the X direction through the first drive member and the second drive member, and then adjust the movement position in the X direction through the ball screw controlled by the servo motor. When the X direction position, X direction inclination, Z direction angle, and Z direction position relative to the fixed coordinate system are within the allowable range of pairing, the gear box 6 moves toward the main shaft 2 for pairing, that is, the gear box 6 moves along the Y direction.

In the above technical solution, the main shaft 2 and the gear box 6 are the two main components of the assembly, and the main shaft 2 can be fixed during the assembly process. The gear box 6 is a moving object, and the adjustment of the gear box 6 is achieved by the tooth position adjustment device 3 to achieve the movement and rotation of the gear box 6.

In order to further improve the assembly accuracy, during the movement of the gear box 6, the control module 5 determines to adjust the positions and angles in various directions according to the real-time monitoring data of the monitoring module to ensure that the relative deviation between the matching part of the gear box and the main shaft in various directions is within the allowable range.

In order to further adjust the matching accuracy of the main shaft and the gear box, the monitoring module 4 also includes a displacement sensor 44, which is arranged on the matching part 8 and is used to measure the distance between the end face of the main shaft 2 and the end face of the matching part 8.

The embodiment of the present application further provides a method for assembling a main shaft and a gearbox for a wind turbine generator set, which comprises the following steps:

Obtain position parameters of the main shaft 2 and the gear box 6 respectively;

Determine the position adjustment information of the gear box 6 relative to the main shaft 2 according to the position parameters of the main shaft 2 and the gear box 6;

The position adjustment information is sent to the position adjustment device 3 to drive the gear box 6 to move relative to the main shaft 2 until the main shaft 2 and the gear box 6 are docked and assembled.

Optionally, the step of respectively acquiring position parameters of the main shaft 2 and the gear box 6 includes determining the positional relationship between the central axes of the main shaft 2 and the gear box 6 .

Furthermore, the step of sending the position adjustment information to the position adjustment device 3 to drive the gear box 6 to move relative to the main shaft 2 includes: determining the angle parameter of the position adjustment information in the horizontal plane, and sending the angle parameter to the position adjustment device 3 to drive the gear box 6 to rotate around the vertical axis.

Optionally, the step of sending the position adjustment information to the position adjustment device 3 to drive the gear box 6 to move relative to the main shaft 2 also includes: determining a first adjustment distance of the position adjustment information on the horizontal second axis, sending the first adjustment distance to the position adjustment device 3, to drive the gear box 6 to move the first adjustment distance on the horizontal second axis; and/or, determining a second adjustment distance of the position adjustment information on the vertical axis, sending the second adjustment distance to the position adjustment device 3, to drive the gear box 6 to move the second adjustment distance on the vertical axis; or adjusting the horizontal inclination angle of the gear box 6.

Optionally, the step of sending the position adjustment information to the position adjustment device 3 to drive the gear box 6 to move relative to the main shaft 2 also includes: determining a third adjustment distance of the position adjustment information on the horizontal first axis, and sending the third adjustment distance to the position adjustment device 3 to drive the gear box 6 to move the third adjustment distance on the horizontal first axis.

Optionally, during the movement of the gearbox 6 on the horizontal first axis, the speed change rate of the gearbox 6 is determined, and when the speed change rate exceeds a fourth threshold range, the gearbox 6 moves in the reverse direction.

Specifically, the relative position parameters of the main shaft 2 and the gear box 6 are obtained and a coordinate system is established; a difference operation is performed according to the relative position parameters of the main shaft 2 and the gear box 6; and the result of the difference operation is distributed to the position adjustment device 3 to drive the gear box 6 to adjust;

The gear box 6 is controlled to move toward the main shaft 2 until the main shaft 2 and the gear box 6 are docked and assembled.

The method for pairing the main shaft and the gearbox also includes the following steps: in the process of the gearbox 6 moving toward the main shaft 2, the real-time position parameters of the main shaft 2 and the gearbox 6 are obtained again and the difference operation is performed, and it is determined whether the real-time operation result is within the predetermined range. When the real-time operation result is within the predetermined range, the gearbox 6 continues the above movement to dock with the main shaft 2; otherwise, the gearbox 6 moves in the opposite direction to the predetermined position.

Referring to FIG. 5 , a specific embodiment of the pairing method provided by the present application is as follows:

Initial alignment stage: A laser alignment instrument can be used to measure the initial position of the main shaft 2 and the mating part 8 of the gear box 6, and combined with the geometric center axis of the main shaft 2 and the mating part 8 measured by the parts scanner 43, the positional relationship of the main shaft 2 and the central axis of the gear box 6 in space can be finally determined.

Coordinate system determination stage. The axis position relationship obtained through the above steps is used to establish an XYZ coordinate system, where the XYZ coordinate system contains parameters (x, y, z, θ _x , θ _z ). Two XYZ coordinate systems are set: the fixed coordinate system X0Y0Z0 on the spindle, the origin is the installation position of the signal generator 41 on the spindle 2, and the Y0 direction is the axis obtained by the part scanner 43. The adjustment coordinate system X1Y1Z1 on the gear box 6, the origin is the installation position of the signal receiver 42 on the gear box 6, and the Y1 direction is the axis obtained by the part scanner 43.

The distance between the signal generator 41 and the signal receiver 42 is L, the distance from the installation position of the signal receiver 42 to the rotation center of the rotating assembly 36 is L1, and the vertical distance between the second driving member 34 and the two first driving members 35 is L2.

Calculate the position adjustment parameters and adjustment stages. Set the parameters of the fixed coordinate system X0Y0Z0 to (0,0,0,0,0), and the parameters of the adjustment coordinate system X1Y1Z1 to (x ₁ ,y ₁ ,z ₁ ,θ _x1 ,θ _z1 ). Perform the difference operation between the adjustment coordinate system and the fixed coordinate system according to formula 1 to obtain the position adjustment parameter ΔXYZ:

ΔXYZ＝X1Y1Z1-X0Y0Z0 (1)

Among them, the parameters of ΔXYZ are ( _Δxn , _Δyn , _Δzn , _Δθxn , _Δθzn ), _Δxn , _Δyn , _Δzn are the nth distance differences measured in the x, y, and z directions respectively, Δθxn, _Δθzn are _the angle differences around the x and z axes respectively, and the angle calculation is positive if it rotates counterclockwise around the coordinate axis.

Among them, the allowable threshold range of the parameter of ΔXYZ is A:

-A＜(Δ x _n , Δ y _n , Δz _n , Δθ _xn , Δθ _zn )＜A (2)

First, the Z-direction angle value may be adjusted. At this time, the control module 5 determines or judges according to Table 1, determines the position adjustment information according to the judgment result, and sends the adjustment information to the position adjustment device to adjust the gear box, that is, to judge whether the Z-direction angle difference is within the first threshold range. When the judgment result is yes, the rotating component 36 is kept inactive; when it is judged that the Z-direction angle difference exceeds the first threshold range and is positive, the rotating component 36 is made counterclockwise Δθ _zn ; when it is judged that the Z-direction angle difference exceeds the first threshold range and is negative, the rotating component 36 is made clockwise Δθ _zn :

Table 1

Difference Judgment conditions Judgment results Adjustment information Δθ _zn Is Δθ _zn within the first threshold range? In the first threshold range Keep the rotating assembly 36 motionless Δθ _zn Is Δθ _zn within the first threshold range? Exceeds the first threshold range and is positive Make the rotating assembly 36 rotate counterclockwise by Δθ _zn Δθ _zn Is Δθ _zn within the first threshold range? Exceeds the first threshold range and is negative Make the rotating assembly 36 rotate clockwise Δθ _zn

The angle value of the inclination in the X direction is adjusted. At this time, the control module determines or judges according to Table 2, and determines the position adjustment information according to the judgment result, and sends the adjustment information to the position adjustment device to adjust the gear box, that is, it is judged whether the angle difference of the inclination in the X direction is within the second threshold range. When the judgment result is yes, the second driving member 34 and the first driving member 35 are kept inactive; when it is judged that the angle difference of the inclination in the X direction exceeds the second threshold range and is positive, the second driving member 34 is lifted by L ₂ tan (Δθ _xn ); when it is judged that the angle difference in the Z direction exceeds the second threshold range and is negative, the second driving member 34 is lowered by L ₂ tan (Δθ _xn ):

Table 2

In the above steps, the X-direction angle adjustment step and the Z-direction angle adjustment step can be performed simultaneously, or the X-direction angle adjustment step can be performed first and then the Z-direction angle adjustment step, or the Z-direction angle adjustment step can be performed first and then the X-direction angle adjustment step. In this embodiment, the angle of the gearbox is adjusted by the second driving member, and it is conceivable that the angle of the gearbox can also be adjusted by the first driving member.

After adjusting the angles in the X and Z directions, the positions of the mating parts of the gearbox and the central axis of the main shaft are monitored again, and the difference (Δx _n+1 , Δy _n+1 , Δz _n+1 ) is determined. Considering the accuracy and cost of the current actuator, after adjusting the angle deviations around the X and Z axes, the target value of the angle deviation may still not meet the requirements. Since some parameters in ΔXYZ affect each other, the angle adjustment results can be calibrated according to Table 3.

In one embodiment of the pairing method of the present application, after the adjustment of Δθ _zn is completed, the angle adjustment result is checked according to Table 3, and the position of the gearbox in the X-axis direction is adjusted accordingly. That is, S1: determine the measured difference Δx _n+1 according to the monitored positions of the mating part of the gearbox and the central axis of the main shaft, and calculate the theoretical difference of the X-axis according to the measured difference Δx _n+ 1 and the angle difference Δθ _zn in the Z direction;

Table 3

S2: Compare the measured difference and the theoretical difference according to Formula 3, and determine whether the comparison result B exceeds the third threshold range:

B = |measured difference - theoretical difference| (3)

If the comparison result is within the third threshold range, the adjustment amount of the gearbox along the X-axis direction is the measured difference Δx _n+1 ; if the comparison result is within or exceeds the third threshold range, the adjustment amount of the gearbox along the X-axis direction is the theoretical difference.

Similarly, the adjustment of the Z axis can refer to the adjustment method of the X axis. After the adjustment of Δθ _xn is completed, the angle adjustment result is checked, and the position of the gearbox in the Z axis direction is adjusted accordingly, that is: the measured difference Δz _n+1 is determined according to the position of the monitored matching part of the gearbox and the central axis of the main shaft, and the theoretical difference of the Z axis is calculated according to the measured difference Δz _n+1 and the angle difference Δθ _xn in the X direction; the measured difference and the theoretical difference in the Z direction are compared, and the adjustment amount of the gearbox along the Z direction is adjusted according to whether the comparison result exceeds the fourth threshold range.

At this point, after the above steps, the axis of the spindle 2 and the gearbox 6 have met the process requirements, and the control module 5 controls the gearbox 6 to move along the Y axis, for example but not limited to, in the opposite direction of the Y axis, until the spindle 2 and the gearbox 6 are paired.

The pairing system of the present application may further include a speed sensor, which can detect the moving speed of the gearbox during the pairing process.

The initial moving speed is v _y0. During the moving process, the moving speed v _y of the gearbox 6 is monitored in real time. If the distance L between the signal generator 41 and the signal receiver 42 is greater than the fifth preset threshold, once the v _y value changes by more than the fourth preset threshold (e.g., a%) of v _y0 , the gearbox 6 is controlled to move in the positive direction of the Y axis to exit the pairing stage. As an example, the a value is obtained by simulating the possible obstruction between the spindle 2 and the gearbox 6 within the allowable matching tolerance.

Closed loop adjustment phase. Once the gearbox 6 exits the pairing phase, the above steps are repeated.

It should be noted here that the above-mentioned embodiments of the present application are based on the relatively fixed position of the main shaft, and the position of the gear box is adjusted to achieve the relative position adjustment of the gear box and the main shaft; those skilled in the art should expect that the above-mentioned pairing device and pairing method can also be set to the relatively fixed position of the gear box, and the position of the main shaft is adjusted to achieve the relative position adjustment of the gear box and the main shaft, in which case the main shaft is arranged on the position adjustment device; or it can also be set so that the positions of both the gear box and the main shaft can be adjusted by the position adjustment device.

It should also be noted that the first threshold range, the second threshold range, the third threshold range, and the fifth threshold range are all determined based on manufacturing tolerances, fitting tolerances, and other process requirements of the gearbox and the main shaft, and the specific numerical values are not limited here.

It should also be noted that the main shaft and gearbox pairing system provided in the present invention is particularly suitable for doubly-fed wind turbine generator sets, but is not limited to this. The above-mentioned pairing system and pairing method can be used in any application scenario that requires pairing of the main shaft and gearbox.

In the description of the present disclosure, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present disclosure.

The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present disclosure, unless otherwise specified, "plurality" means two or more.

In the description of the present disclosure, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection, it can be a mechanical connection, an electrical connection, or a communication connection; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present disclosure can be understood according to specific circumstances.

The features, structures or characteristics described in the present disclosure may be combined in one or more embodiments in any suitable manner. In the above description, many specific details are provided to provide a full understanding of the embodiments of the present disclosure. However, those skilled in the art will appreciate that the technical solutions of the present disclosure may be practiced without one or more of the specific details, or other methods, components, materials, etc. may be adopted. In other cases, known structures, materials or operations are not shown or described in detail to avoid blurring the various aspects of the present disclosure.

Claims (17)

1. A main shaft and gearbox assembly system for a wind turbine generator set, characterized in that the assembly system comprises: A base, used to support the main shaft (2) and the gear box (6); a position adjustment device (3), arranged on the base, for adjusting the relative position of the gear box (6) and the main shaft (2), the position adjustment device (3) comprising a horizontal displacement adjustment unit and a horizontal angle adjustment unit, the horizontal displacement adjustment unit being used to adjust the displacement of the gear box (6) in a horizontal plane, the horizontal angle adjustment unit being used to adjust the angle of the gear box (6) relative to the main shaft (2) in a horizontal plane, the horizontal angle adjustment unit comprising a matching stationary part and a rotating part, the stationary part being connected to the horizontal displacement adjustment unit, the rotating part being able to rotate relative to the stationary part around a vertical axis, and the gear box (6) being connected to the rotating part; A monitoring module (4) for monitoring position parameters of the gear box (6) and the main shaft (2); The control module (5) is capable of receiving the monitoring result of the monitoring module (4) and sending an adjustment signal to the position adjustment device (3) according to the monitoring result, so that the gear box (6) and the main shaft (2) are aligned and matched. 2. The assembly system according to claim 1, characterized in that the horizontal displacement adjustment unit comprises a first position adjustment unit and a second position adjustment unit, the first position adjustment unit is arranged on the base to adjust the position of the gear box (6) on a horizontal first axis, the second position adjustment unit is arranged on the first position adjustment unit to adjust the position of the gear box (6) on a horizontal second axis, and the horizontal angle adjustment unit is arranged on the second position adjustment unit; The position adjustment device (3) also includes a fourth position adjustment unit, which is arranged on the horizontal angle adjustment unit to adjust the height and/or horizontal inclination angle of the gear box (6), and the gear box (6) is supported on the fourth position adjustment unit, wherein the horizontal first axis and the horizontal second axis are perpendicular to each other. 3. The assembly system as described in claim 1 is characterized in that the stationary part and the rotating part are coaxial to form a rotating component; the horizontal angle adjustment unit also includes a servo motor, and the servo motor is fixedly connected to the rotating part. 4. The assembly system according to claim 2, characterized in that the fourth position adjustment unit comprises two first driving members (35) arranged at one end of the gear box (6) close to the main shaft (2), and the two first driving members (35) are symmetrically arranged on both sides of the housing of the gear box (6) along the direction of the horizontal second axis; and/or, The fourth position adjustment unit comprises a second driving member (34) arranged at an end of the gear box (6) away from the main shaft (2), and the second driving member (34) is supported at the bottom of the shell and is located below the central axis of the shell. 5. The assembly system according to claim 4 is characterized in that the base includes a main shaft support part and a gear box support part, wherein the first position adjustment unit is arranged on the gear box support part (14), and the main shaft (2) is supported on the main shaft support part. 6. The assembly system according to claim 5, characterized in that the first position adjustment unit and/or the second position adjustment unit comprises a telescopic assembly or a screw assembly connected to the gear box support portion; and/or, The first driving member (35) and/or the second driving member (34) comprises a telescopic assembly or a screw assembly. 7. The pairing system according to any one of claims 1 to 6, characterized in that the monitoring module comprises a signal generator (41) and a signal receiver (42), and the signal generator (41) can send a signal and be received by the signal receiver (42); The gear box (6) comprises a matching portion (8), wherein the matching portion (8) is assembled with the main shaft (2), the signal generator (41) is arranged on one of the main shaft (2) and the matching portion (8), and the signal receiver (42) is arranged on the other of the main shaft (2) and the matching portion (8) so as to be able to measure the relative position of the matching portion (8) and the main shaft (2). 8. The assembly system as described in claim 7 is characterized in that the monitoring module also includes a part scanner (43) for scanning the geometric center axis of the mating part (8) of the main shaft (2) and/or the gear box (6), and can transmit the scanning result to the control module (5). 9. The pairing system according to claim 8 is characterized in that the monitoring module also includes a displacement sensor (44), which is arranged on the matching part (8) and is used to measure the distance between the end face of the main shaft (2) and the end face of the matching part (8). 10. The assembly system according to claim 8, characterized in that the signal generator (41) is a laser generator, the signal receiver (42) is a laser receiver, and the part scanner (43) is a three-dimensional part scanner. 11. A method for assembling a main shaft and a gearbox for a wind turbine generator set, characterized in that the assembly method uses an assembly system according to any one of claims 1 to 10, and the assembly method comprises the following steps: Obtaining position parameters of the main shaft (2) and the gear box (6) respectively; Determining position adjustment information of the gear box (6) relative to the main shaft (2) according to position parameters of the main shaft (2) and the gear box (6); The position adjustment information is sent to the position adjustment device (3) to drive the gear box (6) to move relative to the main shaft (2) until the main shaft (2) and the gear box (6) are docked and assembled. 12. The pairing method according to claim 11, characterized in that the step of respectively acquiring the position parameters of the main shaft (2) and the gear box (6) comprises determining the positional relationship between the central axes of the main shaft (2) and the gear box (6). 13. The assembly method according to claim 11, characterized in that the step of sending the position adjustment information to the position adjustment device (3) to drive the gear box (6) to move relative to the main shaft (2) comprises: An angle parameter of the position adjustment information in a horizontal plane is determined, and the angle parameter is sent to a position adjustment device (3) to drive the gear box (6) to rotate an angle around a vertical axis. 14. The pairing method as described in claim 13 is characterized in that the pairing method also includes: after the gear box (6) rotates around the vertical axis by an angle, determining the angular deviation between the gear box and the main shaft in the horizontal direction, and determining the measured position difference between the gear box and the main shaft in the vertical direction, determining the adjustment information of the gear box in the vertical direction according to the angular deviation and the measured position difference, and adjusting the position of the gear box in the vertical direction. 15. The assembly method according to claim 13, characterized in that the step of sending the position adjustment information to the position adjustment device (3) to drive the gear box (6) to move relative to the main shaft (2) further comprises: Determining a first adjustment distance of the position adjustment information on the horizontal second axis, sending the first adjustment distance to the position adjustment device (3) to drive the gear box (6) to move the first adjustment distance on the horizontal second axis; and/or, Determine a second adjustment distance of the position adjustment information on the vertical axis, and send the second adjustment distance to the position adjustment device (3) to drive the gear box (6) to move the second adjustment distance on the vertical axis, or drive the gear box to adjust the horizontal inclination angle. 16. The assembly method according to claim 15, characterized in that the step of sending the position adjustment information to the position adjustment device (3) to drive the gear box (6) to move relative to the main shaft (2) further comprises: A third adjustment distance of the position adjustment information on the horizontal first axis is determined, and the third adjustment distance is sent to the position adjustment device (3) to drive the gear box (6) to move the third adjustment distance on the horizontal first axis. 17. The pairing method as described in claim 16 is characterized in that, during the movement of the gear box (6) on the horizontal first axis, the speed change rate of the gear box (6) is determined, and when the speed change rate exceeds a set threshold, the gear box (6) is moved in the reverse direction.