JB/T 10400.2-2004 Gearbox for off-grid wind turbine generator system Part 2: Test methods
Some standard content:
ICS27180
Machinery Industry Standard of the People's Republic of China
JB/T 10400.2-2004
Gearbox of off-grid wind turbine generator systemPart 2: Test method
Published on February 10, 2004
Implementation on June 1, 2004
Published by the National Development and Reform Commission of the People's Republic of ChinaForeword
2 Normative references
3 Requirements for test pieces
7.1 Specification of test pieces and their quantity
3.2 Material and workmanship accuracy of test pieces
4 Requirements for test equipment
Test bench
4.2 Light load and speed tester
4.3 Installation and commissioning.| |tt||Temperature and noise of load test: Requirements for vibration test instruments
Test data and data processing
Data acquisition
Calculate the specific torque power 1, the average speed
Gearbox transmission efficiency..
Gearbox thermal work line
Load energy test and core life test of high-speed gears. Calculate the shear temperature rise and temperature energy of each stress cycle
Labor life test or 1. Industry experience test combined with indicators 8 scientific research track test
To! Sensor installation example
J1/T10400.2-2054
3BT:0400 Off-grid wind turbine gearbox is divided into two parts: Part 1: Technical case:
Part 7: Test method,
This part is the second part of JB/T0100.
This part is formulated for the first time.
IT3T 104C0.2-2504
The writing format and rules of this part conform to the provisions of GB:.1-2000 Standardization Coking Work Guide Part 1: Standard Structure and Writing Rules,
This part is proposed by China Machinery Industry Federation. This part is drafted by the National Wind Power Standardization Technical Committee, and the drafting unit of this part is Nei Yao Ji Tianli Wind Power Machinery Factory. And the main drafters of this part are: Yu Hanjun, Wen Shuiruo, Yang Shenyi. 1 ScopebZxz.net
Off-grid wind turbine gearbox
Part 2: Test methods
This part specifies the test methods for gearboxes for off-grid wind turbines. ET10400.2-2004
This part is mainly applicable to the overall performance test of the broken tooth type gearbox for off-grid wind turbines with a rotor swept area of less than 40m2: the high-speed shaft speed of the test gearbox shall not exceed 2200/m%, and the secondary wheel circumferential speed shall not exceed 20m/5. 2 Normative references
The following documents shall be cited in the same clause as the reference in this part. For references with a date of date, all subsequent amendments (excluding errata) or revisions shall not apply to this part. However, the latest version of these documents may be used by the parties to the agreement reached based on this part. There are no quoted documents without notice, the most appropriate technology for this part is: B-15494-1086 Method for determining the sound power level of step-wheel device (nc91S0464E: 1833 Test requirements
3.1 Test and quantity specifications
The test piece is a factory product or prototype: the number of test sets is determined by the test age and requirements, and there should be no children's pool. 3.2 The material of the test piece, such as length, width, processing width, heat treatment, machining or processing precision, etc., shall comply with the requirements of the drawings, and shall be checked before inspection. The production inspection records or random inspections shall be checked. The main items are: ||tt ||4 Requirements for test equipment
41 Test bench
The drive and speed of the test are not restricted. The main requirements for the test bench: The loading torque and speed are stable, and the fluctuation should not exceed 5%; it should be able to load and unload during circulation. 22 Load and speed test instruments
The specifications, design and specifications of the instruments should be adapted to the test. When the test item is loading speed (rate), the test accuracy should exceed the reading (device). A torque and speed measuring instrument should be used: and one sensor should be installed at the output of the test object, and the test piece should be connected only with the additional connection The input and output torque (average rate) of the shaft) and the speed are shown in Figure 1. 1—Sensor: 2—Test piece, sensor, 4-link chain: 5.7,—Coupling: Connector,
Figure Sensor Installation Example
JH70400.2—2004
4.3 Installation and Debugging
All test equipment (excluding electronic control power supply equipment) should be installed on the same (or combined) platform", and all components should be level and the centering system should be flexible. Perform static zero adjustment first, and then perform dynamic rate adjustment: adjust the torque display value of the instrument. The first few digits of the rate reading should be zero, and the last digit should not be adjusted to zero. 4,
Disconnect the coupling 7 (see 1), and the no-load torque of the test piece 2 can be measured. 5 Requirements for temperature, noise, and vibration test equipment for load test The temperature of the gearbox oil pool and bearing can be measured by a semiconductor temperature meter with a range of up to 150°C.
Noise level and test method should comply with the provisions of T404 of 2006. The vibration test instrument and vibration test method should comply with the relevant provisions. 6 Tests of gearbox products
Test names and test items are shown in Table 1. The test is divided into a) Factory test for batch-produced finalized products and test units. The test items are carried out according to the "no-load test" items in the table. b) For single-piece or small-batch trial production products, finalized products with major improvements, and products designated by the quality supervision agency, type tests should be carried out, and the test items are carried out according to all the items of "no-load test", "load test" and "overload test" in Table 1. ）In order to examine the overload life and safety level of the shuttle, a destructive test should be carried out when necessary: the load is increased step by step in the form and law of the working overload environment after the product leaves the factory, and the number of stress cycles for each forging is 8×10 times until it is destroyed. In order to allow the industrial application test to replace the fatigue life test, the actual industrial application should reach the rated load and have accurate data. The test time is more than 3000h
Testing items
Content and requirements
At a certain speed, the forward and reverse directions are operated for at least 1h each, and the requirements are: all connecting parts and case fixings are not loose; all joints and chain threads are not filled with oil and dripping. The operation is smooth and there is no tooth collision;
The lubrication is sufficient, and the oil tank and bearings are checked step by step. After the air test, the thermal power test is carried out. Under the specified rotation, the loading test is carried out group by group. Each level of load reduction, after the test reaches the oil balance [h], increase one level (about 10 rated load], until the balance degree reaches the allowable amount of clean oil for comparison, and then carry out the mechanical power (mechanical strength) test. Under the desired connection and torque, the number of stress cycles per tooth of the high-speed gear reaches 3×10° times. It is required to measure and change the power efficiency:
Turn and run time:
Bearing and oil temperature, withdrawal:
End sound; disassembly:
Hot surface contact rate: gear damage condition
Under the condition of fixed speed inspection: 120% rated load, run for 1min; 150% rated load, run for 1min;
180% rated load, run for 0.5min, ||tt| |Check the environmental condition of gears and other parts
Under the specified conditions, the stress cycle of high-pressure gears is tested for quenched and tempered gears, and the gears are tested for ×10°. The gear oil is not too high under certain cooling conditions. The lubrication test at high temperature should meet the requirements of hot power test. The engine hot power test can be carried out by cold dragging. The overload test should be carried out after starting. Unload and brake. Test the tooth surface joints for life
? Test data and data processing
7.1 Data acquisition
JT10400.2-20C4
The data collected during the test include: load torque, power, rotation, temperature, noise, vibration, gear wear, time, etc. The data to be collected at least every 30 minutes include input and output speed, output torque, power value, lubricating oil loss, bearing temperature and temperature. The data are collected by the digital display instrument and the typewriter. At least 5 sets of data are collected each time, and the time of data collection is recorded.
Noise and vibration should be measured once for each load level and each speed level, and the noise and vibration values and the corresponding load-free speed and time should be recorded.
The pitting, bonding, fracture and tooth surface contact rate of the gear are generally recorded once. If the test is positive and there is no damage, the recording time interval can be longer. On the contrary, if there is damage on the tooth surface, the recording interval should be shorter. The abnormal conditions, damage, separation and other signs and types of shafts, bearings and machine bodies during the test are recorded. 2. Calculate the average speed (performance) and speed compliance. 2.1 Calculate the average value of each drum data (2)
- The average torque value, unit,
7.-- The torque value in the parent group data, unit is "m·- The average speed value, unit is mln
h-- The speed value in each group of data, unit is r/min: data efficiency.
22 Calculate the average value of each load level
In this case:
, The average torque value of each load level, unit is Nm: Yuan-The average speed value of each sampling, unit is N·m: Yuan. The average speed value of each drum load, unit is r/min: F
The average speed value of each sampling, unit is r/min each The trend of data collection of the series medicine,
7.3 Gear precision transmission efficiency
7.3.1 Gear auxiliary total efficiency
The total efficiency of the gearbox is calculated according to formula (5):
Where:
J日/T10400.2—2004
Force—Total efficiency of gearbox transmission:
The average value of the output torque collected at one time, in units of m yuan—The average value of the input torque collected at the same time, in units of m:—The efficiency of the coupling of the input and output shafts of the gearbox. 7.3.2 Step gear meshing efficiency
The gear combination efficiency is calculated according to formula (6):
Where:
7%——Gear combination efficiency:
Open Here is the total efficiency of each bearing of the gearbox.
7.3.3 Drawing efficiency curve
(6)
Draw the efficiency curves of 25%, 50%, 75%, 100%, and 110% rated load according to the rated speed, take the horizontal axis as the efficiency curve, and the horizontal axis as the load value.
74 Gearbox thermal power curve
Take the thermal power (W) at the allowable high equilibrium temperature as the coordinate and the corresponding speed as the coordinate to draw the relationship between the test thermal power and the speed.
In the .5 Loading performance test and fatigue life test, the number of stress cycles per tooth of the high-pass gear is calculated. The stress cycle is calculated as the number of stress cycles under the specified load, which is equivalent to the rated higher value. The stress under the load is small, and it can be generally calculated according to the formula (?):
or:
N Equivalent stress cycle number
Rated stress cycle number
--- Load lower than the rated load, unit is N - Stress cycle change corresponding to T:
Rated load, unit is N·m.
N=60xa0
N60xn,a
Speed of the commercial gear under rated load, unit is min: n
-T, corresponding rotation: unit is r:min: Number of times each tooth of the small gear rotates: . - Rated load test time, unit is h; - Corresponding test time, unit is
7.B Temperature rise calculation and temperature resistance
Temperature rise calculation and temperature limit are calculated according to the formula (): Wu Zhong:
--the temperature of the lubricant (or bearing. The unit is ℃:+
-lubricant sleeve! Or the temperature of the forced bearing, the unit is: ·Laboratory culvert, the unit is it.
IB/T10406.2—2004
When the oil pool is lubricated with 220, V2.10 and other pressure-breaking wheel parking, the allowable leakage lubrication range is 100℃, or the temperature rise does not reach 80℃. During the heat rate test, the average impact does not exceed 100℃, or the channel rise does not exceed the team death, the mutual load attenuation seat reaches the rated power, then it is the potential power rating
77 Lean life test or industrial application test includes the gear box with a rated load life test or industrial application within 3600h, and its qualified indicators are: 1) There is no breakage between the gear and other parts:
b) There is no bonding or rubbing on the tooth surface:
) The thickness of the tooth wear, measured near the tooth root, does not exceed 4% of the tooth limit number d The limit of cross-sectional pitting area is:
Quenched and tempered gear:
Pe, =Vot.-V2Ca E.2%-
Carburized and calendered gear:
Ven =Pioe +Vece, $ 1%.
Wushan:
V--the percentage of the total area of gear pits to the total effective working area ViEaVaOn
--the percentage of the total effective working area of the gear pitting area V2--the percentage of the pitting area of the gear to the effective working area, 2:
Periodic pitting is allowed to occur, and the initial pitting can be ignored in the pitting area. The characteristics of the initial pitting are rapid improvement of sensitivity, and the diameter of the pitting pit is less than 0.75mm
The test method of the scientific research prototype is basically the same as the test method of the gearbox product in Table 1, but the fatigue life test should be avoided. Data processing should comply with the provisions of the competition.a
The speed of the commercial gear under rated load, in units of min: n
-T, the corresponding rotation: in units of r:min: The number of times each tooth of the small gear rotates: .-The test time under rated load, in units of h;-The corresponding test time, in units of
7.B Temperature rise calculation and temperature resistance
Temperature rise calculation and temperature limit are calculated according to the formula (): Wuzhong:
--the temperature of the lubricant (or bearing. The unit is ℃:+
--the temperature of the lubricant! Or the temperature of the bearing, the unit is: ·Test room culvert, the unit is it.
IB/T10406.2—2004
When the oil pool is lubricated with 220, V2.10 and other pressure-breaking wheels, the allowable leakage lubrication range is 100℃, or the temperature rise is not up to 80℃. During the heat center test, the flat mixing is not questioned. 100℃, or the channel rise does not exceed the team death, the mutual attenuation power seat reaches the rated power, then it is the potential power table
77 lean life test or industrial application test including the qualified pin. The gearbox with a life test or industrial application within 3600h under rated load has the following qualified indicators:) There is no breakage between the gear and the machine parts:
b) There is no bonding or rubbing on the tooth surface:
) The thickness of the tooth replacement grip, measured near the tooth root, does not exceed 4% of the tooth limit number d The limit of the pitting area of the cross section is:
Quenched and tempered gear:
Pe, =Vot.-V2Ca E.2%-
Carburized gear:
Ven =Pioe +Vece, $ 1%.
Wushan:
V--the percentage of the total area of gear pits to the total effective working area ViEaVaOn
--the percentage of the total effective working area of the gear pitting area V2-the percentage of the pitting area of the gear to the effective working area, 2:
The pitting chain is allowed to appear in the long term, and the initial pitting can be ignored in the pitting area. The characteristics of the early pitting are rapid improvement of sensitivity, and the pitting pit diameter is less than 0.75mm
The test method of the scientific research prototype is basically the same as the test method of the gearbox product in Table 1, but the fatigue life test should be avoided. Data processing shall be in accordance with the provisions of Article 2.a
The speed of the commercial gear under rated load, in units of min: n
-T, the corresponding rotation: in units of r:min: The number of times each tooth of the small gear rotates: .-The test time under rated load, in units of h;-The corresponding test time, in units of
7.B Temperature rise calculation and temperature resistance
Temperature rise calculation and temperature limit are calculated according to the formula (): Wuzhong:
--the temperature of the lubricant (or bearing. The unit is ℃:+
--the temperature of the lubricant! Or the temperature of the bearing, the unit is: ·Test room culvert, the unit is it.
IB/T10406.2—2004
When the oil pool is lubricated with 220, V2.10 and other pressure-breaking wheels, the allowable leakage lubrication range is 100℃, or the temperature rise is not up to 80℃. During the heat center test, the flat mixing is not questioned. 100℃, or the channel rise does not exceed the team death, the mutual attenuation power seat reaches the rated power, then it is the potential power table
77 lean life test or industrial application test including the qualified pin. The gearbox with a life test or industrial application within 3600h under rated load has the following qualified indicators:) There is no breakage between the gear and the machine parts:
b) There is no bonding or rubbing on the tooth surface:
) The thickness of the tooth replacement grip, measured near the tooth root, does not exceed 4% of the tooth limit number d The limit of the pitting area of the cross section is:
Quenched and tempered gear:
Pe, =Vot.-V2Ca E.2%-
Carburized gear:
Ven =Pioe +Vece, $ 1%.
Wushan:
V--the percentage of the total area of gear pits to the total effective working area ViEaVaOn
--the percentage of the total effective working area of the gear pitting area V2-the percentage of the pitting area of the gear to the effective working area, 2:
The pitting chain is allowed to appear in the long term, and the initial pitting can be ignored in the pitting area. The characteristics of the early pitting are rapid improvement of sensitivity, and the pitting pit diameter is less than 0.75mm
The test method of the scientific research prototype is basically the same as the test method of the gearbox product in Table 1, but the fatigue life test should be avoided. Data processing shall be in accordance with the provisions of Article 2.
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