轴系对中偏差对单支撑轴系振动的影响

建立了单支撑轴系动力特性分析有限元模型,研究轴系对中偏差对单支撑轴系振动的影响.结果表明:轴系对中偏差会改变中间轴承载荷和油膜刚性,对振动传递特性产生影响;单支撑轴系出现的振动不完全表现在不平衡转子所在跨内;在轴系对中偏差情况下,低压转子不平衡量会在相邻高中压转子上激发起较大振动.     

轴承转子试验台测试系统设计及抗干扰措施

为了识别多支承轴系中的轴承载荷、分析其振动特性和研究动力学行为,设计了四支承轴承转子试验台的测试系统。通过一种测力传感器实现轴承动态载荷的直接测量,采用位移、加速度及扭矩传感器分别获取轴系的轴心轨迹、振动和扭矩等信号,针对实际调试过程中产生的噪声信号采取了有效的抗干扰措施。试验结果表明,测试系统可以对整个轴系进行多参数在线监测,所采集的数据真实可信。     

部分进汽下汽轮机调节级轴系振动失稳试验研究

汽轮机调节级在部分进汽模式下运行容易出现轴系振动失稳现象。对部分进汽下汽轮机调节级轴系振动失稳开展试验研究,搭建了部分进汽模拟试验平台,开展了汽轮机部分进汽下轴系轴承破坏性试验研究。试验中,采集了轴承破坏前试验机组轴承振动的正常信号,以及在超负荷工作后轴承破坏下轴系失稳产生的故障信号。通过对正常信号以及故障信号进行时域分析,比较得出轴系振动失稳的诊断依据。利用快速傅里叶变换对试验数据进行了频谱分析,分析出故障大致发生位置,该结果与机组的实际故障位置吻合。     

1000 MW汽轮机轴承载荷分配测试方法和试验研究

为测试轴承载荷分配,提出了基于转轴截面应变值的轴承载荷测试方法,建立了轴承载荷计算分析模型,研发了测试装置。以某台1 000 MW大型汽轮机为例,测试了轴系连接状态下汽轮机各轴承载荷分配,并据此分析了机组安装时轴系对中状态。试验所得各轴承总载荷与轴系总载荷之间的误差小于1%,单个轴承载荷测试值与设计值之间的误差小于1%,说明本测试方法准确度较高。该汽轮机安装状态下轴系载荷分配与设计值相近,轴系对中状态合理。     

单支撑1000MW汽轮机支承动力特性对轴系振动的影响

针对单支撑1 000 MW汽轮机轴系中低压转子轴承3、轴承4和轴承5振动超标的问题,采用有限元法建立轴系动力学有限元模型,在连接两低压转子联轴器位置施加不平衡激励,分析轴系各轴承处振动对联轴器处不平衡量的敏感性.通过调整支撑两低压转子轴承4入口油温的方式来改变其支承动力特性,并研究了其动力特性对轴系稳态响应的影响.结果表明:支承4的动力特性对支撑低压转子2的轴承5处振动影响最大,轴承4次之,而对支撑高压转子的轴承1和轴承2处振动影响相对较小;在工程实际过程中,可适当提高轴承4的入口油温来减小轴系振动.     

汽轮机轴系动力特性研究

以某国产大型汽轮机组为例，利用传递矩阵法原理和相关的软件包，计算并分析了轴系的稳定性和不平衡响应，求出了系统的阻尼临界转速，并研究了轴承标高变化对负荷分配的影响以及扭振特性等，涉及汽轮机轴系动力特性的大多数领域。结果表明，分析方法完全满足工程精度要求，可以用于大型汽轮机组轴系的动力特性分析。     

某1000MW汽轮发电机组轴承载荷灵敏度计算分析

大型汽轮发电机组是一个多支撑结构,轴系中任一轴承标高的变化都将影响所有轴承的载荷分配,因此研究轴承栽荷灵敏度对机组稳定运行非常重要.利用传递矩阵法计算了某1 000 MW机组轴系扬度曲线及轴承载荷与灵敏度,对比分析了计算扬度曲线与实测曲线,两者在轴系中问吻合较好.两端差别较大.由计算扬度曲线与实测扬度曲线分别计算了轴系各轴承载荷分布情况,由计算扬度值得出的同根转子轴承载荷分配较为均匀.结合载荷对标高变化的灵敏度分析了该机组轴承栽荷对标高变化规律,端部轴承对裁荷的灵敏度较小,而中间部位较大.分析结果对该机组运行有指导意义.     

基于轴系对中数据的轴承载荷识别方法

基于汽轮发电机组轴系对中检测数据,应用传递矩阵方法建立了轴承载荷识别模型,首先由对中数据识别轴承标高,然后由轴承标高计算轴承载荷．以某350MW汽轮发电机组为例进行了计算,分析了张口和高低差对轴承载荷的影响以及3种不同对中状态下的载荷分配．结果表明：该方法可有效地由轴系中心检测数据识别轴承标高和轴承栽荷;理想对中状态下,各对轮处的张口和高低差为0;检修后低速盘车状态下,1号、2号轴承顶轴油压相近,2个轴承的载荷分配基本均匀;满负荷运转状态下,轴系振动稳定,消除了突发性不稳定振动现象．     

艉管后轴承多支点模拟探讨

基于目前大多数主机厂在进行轴系校中计算时,仍根据自身经验对艉管后轴承进行单支点模拟的现状,分别对艉管后轴承进行单支点和多支点模拟计算后发现:对于采用偏心加工的艉管后轴承,多支点计算准确度更高。同时鉴于目前广泛使用的顶举法校中是以轴系校中计算书中的轴系负荷为校中验收依据,指出:如校中计算不准确会给船舶的运营带来巨大风险。据此建议:大型船舶的轴系校中计算,艉管后轴承进行多支点模拟,以消除轴系校中安装过程中的隐患。     

考虑横—纵—扭支撑刚度的水轮发电机组轴系预应力模态分析

综合考虑导轴承和推力轴承的支撑刚度对轴系的横—纵—扭耦合影响,应用Ansys Workbench软件建立了悬式三支点水轮发电机组轴系的三维有限元模型,采用Block Lanczos模态分析法分析了轴系的固有频率及其振型,借助Design Exploration优化设计模块计算了机组实际运行时轴系的预应力模态,获得了水流冲击和转速变化等因素对机组轴系固有频率值的影响规律。结果表明,机组在运行过程中转速变化对轴系的低阶横向振动频率影响较大,而对其扭转振动频率影响很小。     

国产600MW汽轮发电机组轴系动平衡研究

针对国产600MW汽轮发电机组运行中普遍存在的轴系异常振动问题,分析了振动现象、振动特征、振动机理及其原因,并对现场动平衡问题的处理方法进行了总结.结果表明：国产600MW高中压转子由于结构不对称存在较大的振型干扰,现场对转子进行动平衡时应考虑各阶振型的干扰系数,尤其是一阶配重对二阶振型的影响;部分机组低压转子轴承座振动超标的原因为采用坐缸式轴承座的支承刚度不足,现场可以通过精细动平衡来消除;发电机转子振动主要呈现三阶振型,现场校正三阶不平衡的方法就是在低-发对轮或发-励对轮上加重,且在动平衡分析时应注意区分振型畸变;集电小轴的振动受发-励对轮的安装工况影响较大,现场对其进行动平衡分析时应考虑发-励对轮下张口对加重响应的影响.     

Investigation of high‐speed shaft bearing loads in wind turbine gearboxes through dynamometer testing

Many wind turbine gearboxes require repair or replacement well before reaching the end of their design life. The most common failure is bearing axial cracks, commonly called white etching cracks (WECs), which typically occur in the inner raceways of the high‐speed parallel‐stage rolling element bearings. Although the root causes of WECs are debated, one theory is that they are related to routine dynamic operating conditions and occasional transient events prevalent in wind turbines that can result in high bearing stress and sliding of the rolling elements. This paper examined wind turbine gearbox high‐speed shaft bearing loads and stresses through modeling and full‐scale dynamometer testing. Bearing outer race loads were directly measured and predicted using a variety of modeling tools in normal operations, misaligned conditions, and transient events particularly prone to bearing sliding. Test data and models of bearing loads were well correlated. Neither operational misalignment due to rotor moments nor static generator misalignment affected the bearing loads when compared with pure‐torque conditions. Thus, it is not likely that generator misalignment is a causal factor of WECs. In contrast, during transient events, the bearings experienced alternating periods of high stress, torque reversals, and loads under the minimum requisite at high rotating speeds while showing indications of sliding, all of which could be related to the formation of WECs.     

超临界汽轮机高中压转子弯曲及异常振动的分析与处理

针对部分660 MW超临界汽轮机在试生产阶段发生的高中压转子永久性弯曲事故,通过研究各机组的异常振动特征及其发展趋势,分析了高中压转子残余内应力的形成机理及其分布规律,确定了转子弯曲的主要原因是:热处理不当导致部分轴段形成残余内应力,并进而引发强烈轴振.为此,对转子再次采取适当的去应力回火技术,并结合机械切削加工和高速动平衡技术,消除了弯曲与振动异常.此外,还提出了一些合理的建议.     

计入曲轴倾斜时曲轴-轴承系统动力学摩擦学和弹性力学耦合分析

采用动力学仿真软件ADAMS和有限元分析软件ANSYS,辅以手工编程相结合的方法,研究了计入曲轴倾斜时某4缸柴油机曲轴-轴承系统动力学、摩擦学和弹性力学(曲轴的刚度和强度)耦合分析问题.根据耦合特点,先解决曲轴-轴承系统动力学、摩擦学和刚度耦合析问题,再解决曲轴动应力计算问题的解耦方法.研究结果表明:计入曲轴颈倾斜,主轴承最小油膜厚度大幅度下降,最大油膜压力大幅度上升,曲轴动力学响应也发生变化,曲轴疲劳寿命下降23.24 %.     

某发电机前联轴器与轴连接结构应力的有限元分析

某600MW发电机前联轴器与轴过盈连接结构体在运行期间出现了多处裂纹.采用线弹性有限元法,对该结构体进行了应力计算.计算考虑了多种过盈量和多种载荷,得到了该结构体相应工况下的应力分布,分析了此结构在运行状态下的受力特点及应力分布规律,探讨了产生裂纹的原因.可为此类联轴器与转轴连接结构的强度设计提供参考.     

Performance tests on helical Savonius rotors

Conventional Savonius rotors have high coefficient of static torque at certain rotor angles and a negative coefficient of static torque from 135° to 165° and from 315° to 345° in one cycle of 360°. In order to decrease this variation in static torque from 0° to 360°, a helical Savonius rotor with a twist of 90° is proposed. In this study, tests on helical Savonius rotors are conducted in an open jet wind tunnel. Coefficient of static torque, coefficient of torque and coefficient of power for each helical Savonius rotor are measured. The performance of helical rotor with shaft between the end plates and helical rotor without shaft between the end plates at different overlap ratios namely 0.0, 0.1 and 0.16 is compared. Helical Savonius rotor without shaft is also compared with the performance of the conventional Savonius rotor. The results indicate that all the helical Savonius rotors have positive coefficient of static torque at all the rotor angles. The helical rotors with shaft have lower coefficient of power than the helical rotors without shaft. Helical rotor without shaft at an overlap ratio of 0.0 and an aspect ratio of 0.88 is found to have almost the same coefficient of power when compared with the conventional Savonius rotor. Correlation for coefficient of torque and power is developed for helical Savonius rotor for a range of Reynolds numbers studied.     

Effects of eccentricities on shaft signals studied throughwindingless rotors

Shaft signals of electric rotating machines offer potentials for defect detection. The signals are affected by many factors. This study specifically focuses on how eccentricities affect shaft signals through theoretical predictions and tests conducted on windingless rotors. Windingless rotors imply currentless rotors. For symmetrical synchronous machines running at steady synchronous speeds, the induced rotor currents are zero, while harmonics are neglected. One advantage in experiments for this study is that air gaps can be shimmed accurately at standstill without end brackets; certain tests can be conducted at standstill without facing unmanageable locked-rotor currents for the test machines. Shaft signals decrease when the rotor of a machine closely situates at the center of stator bore. Shaft signals increase under greater eccentricities when stator and rotor axes are parallel. Tilted rotors reduce shaft signals. Even when there are no rotor windings, inherent positional characteristics exists. This characteristic produces cyclic shaft-signal components that are related to rotor revolutions     

Improving wind turbine drivetrain bearing reliability through pre‐misalignment

Improving the reliability of wind turbines (WT) is an essential component in the bid to minimize the cost of energy, especially for offshore wind because of the difficulties associated with access for maintenance. Numerous studies have shown that WT gearbox and generator failure rates are unacceptably high, particularly given the long downtime incurred per failure. There is evidence that bearing failures of the gearbox high‐speed stage (HSS) and generator account for a significant proportion of these failures. However, the root causes of these failure data are not known, and there is therefore a need for fundamental computational studies to support the valuable ‘top down’ reliability analyses. In this paper, a real (proprietary) 2 MW geared WT was modelled to compute the gearbox–generator misalignment and predict the impact of this misalignment upon the gearbox HSS and generator bearings. At rated torque, misalignment between the gearbox and generator of 8500 µm was seen. For the 2 MW WT analysed, the computational data show that the L₁₀ fatigue lives of the gearbox HSS bearings were not significantly affected by this misalignment but that the L₁₀ fatigue lives of the generator bearings, particularly the drive‐end bearing, could be significantly reduced. It is proposed to apply a nominal offset to the generator to reduce the misalignment under operation, thereby reducing the loading on the gearbox HSS and generator bearings. The value of performing integrated system analyses has been demonstrated, and a robust methodology has been outlined. Copyright © 2013 John Wiley & Sons, Ltd.     

汽轮机焊接转子接头残余应力研究一:25Cr2Ni2MoV钢核电转子模拟件热处理前后残余应力的对比

利用焊接方法制造大型汽轮机转子已成为电力装备制造业的主要方向,通过测量焊接转子模拟件接头处的残余应力,对于转子设计、优化焊接与热处理工艺、评估服役状态都具有重要的参考意义。测试了25Cr2N i2MoV钢核电转子模拟件外圆、内圆、剖面处热处理前后的残余应力分布,发现转子深窄间隙接头处存在较为显著的轴向压应力,内、外圈在热处理前均有较大的切向拉应力;经过热处理,残余应力大大降低,且保持较好的应力状态。重复性测量的数据稳定性较好,反映出加工过程的高稳定性。     

300MW合缸汽轮机高中压转子现场直轴

300MW合缸汽轮机组的高中压转子是国内目前运行汽轮机的较大转子之一,此类转子轴的直径大、跨距长,校直难度较大。本文论述了华北电科院使用可移动式直轴设备,采用目前较先进的松弛法直轴,在电厂厂房检修场地内成功地完成了某电厂6号机组高中压转子的直轴工作,为机组的抢修节约了时间,其经济效益和社会效益巨大。