兆瓦级风机偏航齿轮箱中心轮断轴原因  

Reason for the center wheel of the yaw gearbox of a megawatt level wind turbine breaking shaft

作　　者：厉旭旺 金子文 李贵方 李玉志 黄成彦 魏煜锋 LI Xuwang;JIN Ziwen;LI Guifang;LI Yuzhi;HUANG Chengyan;WEI Yufeng(Ming Yang Smart Energy Group Co.,Ltd.,Zhongshan 528437,China)

机构地区：[1]明阳智慧能源集团股份公司,中山528437

出　　处：《理化检验(物理分册)》2025年第2期61-68,共8页Physical Testing and Chemical Analysis(Part A:Physical Testing)

基　　金：广东省重点领域研发计划项目(2021B0101230002);广东省海洋经济发展专项资金项目(粤自然资合[2022]25号)。

摘　　要：某兆瓦级风机并网运行3 a后,偏航驱动齿轮箱的4级中心轮发生断轴事故。采用宏观观察、安全性分析、化学成分分析、力学性能测试、金相检验、扫描电镜及能谱分析等方法,并结合有限元仿真分析,对中心轮断裂的原因进行分析。结果表明:中心轮断口处存在多处非金属夹杂物,导致材料的极限强度降低;轴肩过渡区设计尺寸过小,且轴肩表面残留多处粗糙的加工刀痕,导致轴肩成为危险截面并产生应力集中,使材料发生扭转疲劳开裂,裂纹不断扩展,直至残余材料的强度不足,最终导致中心轮发生断轴事故。After a certain megawatt level wind turbine was connected to the grid for 3 years,the 4th stage center wheel of the yaw drive gearbox experienced a shaft breakage accident.Using macroscopic observation,safety analysis,chemical composition analysis,mechanical property testing,metallographic examination,scanning electron microscopy and energy spectrum analysis methods,combined with finite simulation analysis,the causes of the center wheel fracture were analyzed.The results show that there were multiple non-metallic inclusions at the fracture surface of the central wheel,led to a decrease in the ultimate strength of the material.The design size of the shoulder transition zone was too small,and there were multiple rough processing knife marks remaining on the shoulder surface,which made the shoulder a dangerous section and generated stress concentration,caused the material to undergo torsional fatigue cracking.The cracks continued to propagate until the strength of the residual material was insufficient,ultimately led to a broken shaft accident in the center wheel.

关 键 词：偏航驱动中心轮 断轴 非金属夹杂物 有限元仿真 轴肩过渡区 

分 类 号：TB31[一般工业技术—材料科学与工程] TG142.1[金属学及工艺—金属材料]