Fault Analysis and Adaptive Design of Wind Turbine Lubrication System

doi:10.23940/ijpe.19.02.p8.431440

Abstract

Abstract:

Wind turbines work in harsh environments and have changeable loads. The reliability and service life of the wind turbine gearbox has become an important factor for maintaining its safe, stable, and reliable economic operation. The production practice shows that the failure of the wind turbine gearbox is closely related to the structure and performance of the lubrication system. In this paper, the fault tree of the wind turbine gearbox lubrication system is established. It is pointed out that the temperature, state, and lubrication intensity of the lubricating oil are not well adapted to the working condition of the gear box, which leads to frequent gearbox breakdowns until its failure. The heat dissipation power consumption of the lubrication system is determined by calculating the heat balance of the lubrication system. By introducing the AI control method, the adaptive lubrication system framework of the wind turbine gear box is constructed from the aspects of oil temperature, oil pressure, oil level, and oil quality, which can automatically adjust the lubrication intensity according to the working condition of the wind turbine, so as to improve the lubrication effect of the wind turbine gear box. The research work in this paper plays an important role in optimizing the performance of the lubrication system, reducing the failure of the lubrication system, and reducing the operation and maintenance cost of wind turbines.

Key words: lubrication system fault tree, adaptive design, wind turbine

Haitang Cen, Tianfang Zhang, Wenliang Tian, and Yongdong Zheng. Fault Analysis and Adaptive Design of Wind Turbine Lubrication System [J]. Int J Performability Eng, 2019, 15(2): 431-440.

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References 14

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Components of the lubrication system	Main function	Effect of failure
Oil storage device	Store lubricating oil	Lube oil leakage
Oil supply device	Pressurization for lubricating oil	Low oil pressure in lubricating system
Filter device	Remove impurities from lubricating oil	Excessive impurities in lubricating oil aggravate the wear of moving parts
Cooling and heating device	Maintain the normal working temperature of the lubricating oil	Oil temperature anomaly
Lubricating line	For conveying lubricating oil	Oil pressure anomaly, lubricating oil leakage
Sensor	Testing lubrication system	System misreport

Serial number	Event description	Serial number	Event description
A1	Oil temperature anomaly	X8	Low viscosity of lubricating oil
A2	Oil pressure anomaly	X9	Serious wear and tear of the main and passive gear
A3	Anomaly of oil level	X10	Inhalation of foam or air
A4	Poor oil quality	X11	Oil road blockage
B1	Oil temperature too high	X12	High viscosity of lubricating oil
B2	Oil temperature too Low	X13	Poor heat dissipation
B3	Oil pressure too high	X14	Electronic component failure
B4	Oil pressure too low	X15	Power supply voltage anomaly
B5	Oil level too high	X16	Circuit short circuit or circuit breakage
B6	Oil level too low	X17	Oil road blockage
C1	Mechanical pump failure	X18	High viscosity of lubricating oil
C2	Electric pump failure	X19	Abnormal work of a dragged gear pump
C3	Lube oil leakage	X20	line fault
D1	Mechanical overload	X21	Oil pressure too high
D2	Motor overheating	X22	Overabundance of bubbles in lubricating oil
D3	motor overload	X23	Seal ring damage
D4	Motor does not start	X24	Pipe joint loosening
D5	Larger vibration noise	X25	Lubricating oil pipeline breakage
X1	Long term full load operation	X26	Overabundance of oil
X2	Gear box component damage	X27	Insufficient oil
X3	Work anomaly of cooling system	X28	The viscosity of the lubricating oil is too high to cause misreport
X4	Low ambient temperature	X29	Long term high temperature lead to lubricating oil
X5	Abnormal heating system of lubricating oil	X30	Filtering system work exception
X6	High viscosity of lubricating oil	X31	Lubricating oil modification emulsification
X7	Filter system bypass valve pressure is too high

Bearing type	Lubricating type
Bearing type	Oil mist	Oil bath	Oil jet lubrication
Deep groove ball bearing single row Double row	1 2	2 4	4 8

Bearing type	f₁	P₁
Deep groove ball bearing	0.0003(P₀/ C₀)0.4	1.4Y₂Fa-0.1Fr
Angle contact ball bearing single row Double row	0.001(P₀/ C₀)0.33 0.001(P₀/ C₀)0.33	Fa-0.1Fr 1.4Y₂Fa-0.1Fr
P₀ is bearing equivalent static load P₁ is a bearing equivalent dynamic load C₀ is the basic rated static load of the bearing Fa is the axial load of bearing Radial load of Fr bearing If P₁<Fr,P₁= Fr

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