Wind Energy Gearbox Gears

 

 

High-quality wind turbine gears have the characteristics of high strength, high reliability, long service life, low noise, etc., and can adapt to complex and changeable working environments, meeting the needs of large-scale wind turbines and offshore wind power.

Relying on innovation and zero-defect quality concepts, HISCORE continues to increase R&D investment to provide the global market with a full range of wind power transmission products covering 1.5 MW - 20+ MW, and at the same time with a complete service network. The products can adapt to various working conditions such as low temperature, high temperature, low wind speed, high altitude, desert, and offshore. To date, HISCORE has provided customers with more than 108,000 high-quality wind turbine main gearbox gears and more than 620,000 yaw and pitch gearbox gears, which are safely and stably operated in more than 30 countries around the world.

 

 

 

1. High Strength:As a key component of the transmission device, wind turbine gears need to have high strength. The transmission torque and torque they bear are large, so the gears are required to have high strength and be able to withstand certain impact loads and torques. High-strength wind turbine gears can improve the working efficiency and transmission accuracy of equipment, reduce failure rate and maintenance costs.

2. High Reliability:Wind turbine gears play a key role in wind turbines, so their reliability is very important. High-quality wind turbine gears have high reliability and stability, can operate stably for a long time, and reduce failure rate and repair costs. At the same time, high-reliability wind turbine gears can also improve the power utilization rate and power generation efficiency of wind turbines, and contribute to sustainable development.

3. Long Service Life:High-quality wind turbine gears have a long service life and can ensure the long-term safe operation of wind turbines. Wind turbine gears with long service life can also reduce the number of repairs and replacement costs, improve maintenance efficiency and economic benefits.

4. Low Noise:High-quality wind turbine gears have the characteristics of low noise during operation, which can reduce the generation of environmental noise and ensure the safety and environmental friendliness of wind turbines. Low-noise wind turbine gears can not only reduce pollution to the environment, but also help improve the working efficiency and power generation capacity of wind turbines and improve energy utilization.

5. Adapt to complex environment:The working environment of wind turbine gearbox is harsh, and it needs to adapt to the complex and changeable wind resources and environmental conditions in the sea, plateau and desert for a long time. Therefore, wind turbine gearbox has strict requirements on the materials, quality, mechanical properties, corrosion resistance and other special components.

6. Adapt to the needs of large-scale wind turbines:With the rapid development of large-scale wind turbines and offshore wind power, the energy density per unit area of wind turbine gearboxes has increased, and it is necessary to increase the transmission power and torque, enhance the carrying capacity, improve reliability, and extend the design life. Therefore, special components of wind turbine gearboxes need to have higher material strength and toughness, fatigue resistance and other characteristics.

HISCORE has achieved mass production and supplied it to domestic and foreign users. The gearbox speed ratio can be matched according to user needs, and the gearbox can also be customized according to user needs for different application scenarios such as offshore, onshore, plateau, high temperature, and desert.

 

 

 

 

The gearbox is an important component in the wind turbine. Its main function is to accelerate the rotation of the rotor shaft and drive the generator to generate electricity. The energy is transmitted from the wind rotor main shaft to the gearbox through the wind rotor blades, and finally to the generator through the flexible coupling.

Since the speed of the impeller is very low, it is far from the speed required by the generator to generate electricity. It must be achieved through the speed increase of the gearbox gear. Therefore, the design and manufacture of the speed increase gearbox are quite critical. At the same time, due to the limitations of its use conditions, the speed increase gearbox of the wind turbine generator set requires small size, light weight, excellent performance, reliable operation and low failure rate. The gearboxes on the most used double-fed models are mostly planetary gear trains + parallel shaft transmission.

 

1. Gears

Common gear transmissions are also divided into many types: cylindrical gears, bevel gears, internal meshing gears, worm gears, helical gears, and planetary gears.

 

1) Planetary gear train

The planetary gear train consists of a sun gear plus three planetary gears on the planetary carrier, and a large gear ring on the outside.

Because of the use of a load-balancing mechanism, that is, several planetary gears with the same structure are evenly distributed around the center wheel, the forces on the planetary gears and the swing arm can be balanced. At the same time, the number of teeth involved in the meshing is increased, so the load-bearing capacity, meshing stability and reliability of the gears can be improved.

 

2) Parallel shaft system

The parallel shaft system gears are mainly driven by the driving wheel to drive the driven wheel for transmission.

The advantages of planetary gear trains over parallel shaft systems are: compact structure, small size, small mass, large load capacity, low noise, etc.; while the disadvantages are: complex structure, high processing requirements, high assembly requirements, etc.

 

3) Gear failure

Gears also have extremely strict requirements for material selection and manufacturing processes, otherwise they are easily damaged. The following are the five main forms of gear failure:

Breakage: eccentric load, overload, severe impact, heat treatment;

Pitting: surface crack expansion, abrasive particles, peeling;

Bonding: local heating and heavy load, insufficient lubrication, oil deterioration, low gear precision;

Plastic deformation: heavy load, heat treatment;

Wear: metal particles, dust, unclean lubricant.

 

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