风力发电机偏航齿轮箱太阳轮断齿失效分析  

Failure analysis of solar wheel broken teeth of wind turbine yaw drives

作　　者：厉旭旺 黄成彦 李贵方 范焕 王瀚 魏煜锋 LI Xuwang;HUANG Chengyan;LI Guifang;FAN Huan;WANG Han;WEI Yufeng(Wind Energy Institute,Mingyang Smart Energy Group Company Limited,Zhongshan 528437,China)

机构地区：[1]明阳智慧能源集团股份公司风能研究院,中山528437

出　　处：《机械传动》2025年第2期118-124,共7页Journal of Mechanical Transmission

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：【目的】偏航系统的疲劳载荷是风力发电机产生故障的主要原因,偏航驱动等齿轮箱断齿、断轴现象仍为高频故障。失效分析结果表明,原材料的生产工艺、组织调控结果、宏观力学性能调配、部件装配间隙、啮合关系、振动影响是主要的失效原因。研究分析这些规律,可以查明陆上风机偏航驱动齿轮箱太阳轮输出齿的断齿故障原因,为后续风机的偏航系统研究设计提供技术支撑。【方法】通过对失效输出齿的理化性能测试、SEM断口分析,排查了齿轮结构设计、机组运行状态,确定了断齿原因。【结果】结果表明,输出齿的表层马氏体组织异常分解,导致表面硬度不足58 HRC、硬化层深度偏浅10%,降低了轮齿的表面接触强度;断面残留多个约5μm非金属夹杂物,齿根表面机加工刀痕粗糙,降低了轮齿齿根弯曲强度;运行过程中齿条间有效啮合区仅50%,存在严重偏载,导致轮齿工作应力超出许用应力,诱发齿面疲劳磨损及早期开裂,后期载荷超出承载极限时产生断齿。该偏载断齿现象经机加工艺及齿形优化后有一定改善。[Objective]The fatigue load of the yaw system is the main cause of wind turbine failures,and the phenomenon of gear and shaft breakage in yaw drive and other gearboxes is still a high-frequency fault.The failure analysis results indicate that the production process of raw materials,organizational control results,macroscopic mechanical performance adjustment,component assembly clearance,meshing relationship,and vibration influence are the main causes of failure.By studying and analyzing these patterns,the cause of tooth breakage in the output teeth of the sun gear in the yaw drive gearbox of onshore wind turbines can be identified,providing technical support for the subsequent research and design of wind turbine yaw systems.[Methods]Through physical and chemical performance testing of failed output teeth and SEM fracture analysis,the gear structure design and unit operating status were investigated to determine the cause of tooth breakage.[Results]The results show that the abnormal decomposition of the martensitic structure on the surface layer of the output tooth resulted in a surface hardness below 58 HRC and a shallower hardening layer depth by 10%,which reduced the surface contact strength of the tooth.Multiple non-metallic inclusions about 5 micrometers were found on the fracture surface,and rough machining marks on the tooth root surface further reduced the bending strength of the tooth root.During operation,the effective meshing area between the gear racks was only 50%,indicating severe uneven loading.This resulted in the working stress of the teeth exceeding the allowable stress,triggering fatigue wear and early cracking on the tooth surface,and causing tooth fracture when the load exceeds the bearing limit.The phenomenon of partial load broken tooth is improved after machining technique and tooth shape optimization.

关 键 词：太阳轮 失效 非金属夹杂物 组织异常 偏载 

分 类 号：TH114[机械工程—机械设计及理论]