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Title:
GEARBOX METALLIC PARTICLES DETECTION SYSTEM AND GEARBOX METALLIC PARTICLES DETECTION METHOD
Document Type and Number:
WIPO Patent Application WO/2019/145160
Kind Code:
A1
Abstract:
The present invention discloses a gearbox metallic wear warning system that minimizes the risk of severe incidents, preferably in the gear box of a wind turbine comprising said gearbox metallic particles detection system. The invention also concerns to the gearbox metallic wear warning method. Gearbox metallic particles detection system specifically comprises a perforated metallic pipe (1) defining a longitudinal direction corresponding to a longitudinal axis (7) of the perforated metallic pipe (1); a set of magnets (2) disposed inside the perforated metallic pipe, the set of magnets (2) comprising at least two magnets (2); a set of insulation elements (3) disposed inside the perforated metallic pipe (1), the set of insulation elements (3) comprising at least one insulation element (3), wherein at least one insulation element (3) of the set of insulation elements (3) is disposed between the at least two magnets (2) of the set of magnets (2); and voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1) and the set of magnets (2).

Inventors:
CHINNASWAMY, Vijay (#472, F14 Grihalaxmi Apartment, TH high road, Tondiarpet, Chennai 1, 600081, IN)
Application Number:
EP2019/050565
Publication Date:
August 01, 2019
Filing Date:
January 10, 2019
Export Citation:
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Assignee:
SIEMENS GAMESA RENEWABLE ENERGY INNOVATION AND TECHNOLOGY S.L. (Parque Tecnológico de Bizkaia, edificio 222 Zamudio, Vizcaya, 48170, ES)
International Classes:
B03C1/00; G01N15/06
Foreign References:
US20020145530A12002-10-10
US5264832A1993-11-23
Attorney, Agent or Firm:
ASPACHER, Karl-Georg (Postfach 22 16 34, München, 80506, DE)
Download PDF:
Claims:
CLAIMS

1. Gearbox metallic particles detection system characterized in that it comprises:

- a perforated metallic pipe (1 ) defining a longitudinal direction corresponding to a longitudinal axis (7) of the perforated metallic pipe

(1 );

- a set of magnets (2) disposed inside the perforated metallic pipe, the set of magnets (2) comprising at least two magnets (2);

- a set of insulation elements (3) disposed inside the perforated metallic pipe (1 ), the set of insulation elements (3) comprising at least one insulation element (3), wherein at least one insulation element (3) of the set of insulation elements (3) is disposed between the at least two magnets (2) of the set of magnets (2); and

- voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2). 2. Gearbox metallic particles detection system according to claim 1 characterized in that it further comprises an alarm device configured to be activated if the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) is greater than a predetermined threshold value, being preferably the predetermined threshold value of 24V at 2.25A.

3. Gearbox metallic particles detection system according to any one of the previous claims characterized in that the at least two magnets (2) of the set of magnets (2) disposed inside the perforated metallic pipe (1 ) are disposed along the longitudinal direction.

4. Gearbox metallic particles detection system according to claim 3 characterized in that the at least one insulation element (3) of the set of insulation elements (3) disposed inside the perforated metallic pipe (1 ) is disposed along the longitudinal direction.

5. Gearbox metallic particles detection system according to any one of the previous claims characterized in that the perforated metallic pipe (1 ) is a perforated aluminium pipe (1 ). 6. Gearbox metallic particles detection system according to any one of the previous claims characterized in that each one of the at least two magnets (2) of the set of magnets (2) disposed inside the perforated metallic pipe, is a disc shaped magnet (2), more preferably a disc shaped permanent magnet (2).

7. Gearbox metallic particles detection system according to any one of the previous claims characterized in that the at least one insulation element (3) of the set of insulation elements (3) disposed inside the perforated metallic pipe (1 ) is a disc shaped insulation element (3), more preferably a tape insulation element circumferentially disposed around the axis of the perforated metallic pipe (7).

8. Gearbox metallic particles detection system according to any one of the previous claims characterized in that the longitudinal axis (7) of the perforated metallic pipe (1 ) is a metallic longitudinal axis (7), more preferably an aluminium longitudinal axis (7).

9. Gearbox metallic particles detection system according to any one of the previous claims characterized in that the voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) comprises a first wire (4) connected to the perforated metallic pipe (1 ) a second wire (5) connected to the set of magnets (2) and a device (6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2).

10. Wind turbine comprising at least a gearbox (20) and a gearbox metallic particles detection system of any one of the previous claims.

11. Wind farm comprising at least one wind turbine of claim 10.

12. Gearbox metallic particles detection method using a gearbox metallic particles detection comprising:

- a perforated metallic pipe (1 ) defining a longitudinal direction corresponding to a longitudinal axis (7) of the perforated metallic pipe (1 );

- a set of magnets (2) disposed inside the perforated metallic pipe, the set of magnets (2) comprising at least two magnets (2);

- a set of insulation elements (3) disposed inside the perforated metallic pipe (1 ), the set of insulation elements (3) comprising at least one insulation element (3), wherein at least one insulation element (3) of the set of insulation elements (3) is disposed between the at least two magnets (2) of the set of magnets (2); and

- voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2);

characterized in that the method comprises a step of measuring the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2).

13. Gearbox metallic particles detection method according to claim 12 characterized in that the method further comprises a step of activating an alarm device if the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) is greater than a predetermined threshold value, being preferably the predetermined threshold value of 24V at 2.25A.

Description:
GEARBOX METALLIC PARTICLES DETECTION SYSTEM AND

GEARBOX METALLIC PARTICLES DETECTION METHOD

DESCRIPTION

OBJECT OF THE INVENTION

The present invention discloses a gearbox metallic wear warning system that minimizes the risk of severe incidents, preferably in the gear box of a wind turbine comprising said gearbox metallic particles detection system. The invention also concerns to the gearbox metallic wear warning method.

BACKGROUND OF THE INVENTION Modern wind turbines are provided with gearboxes whereby a driving shaft is coupled to the rotor of a wind turbine and whereby a sun gear of the gear unit drives for example a generator

In the conventional embodiments, the housing of the gearbox is made of several pieces, whereby a first part of the housing is for example a part of the supporting structure in which a couple of main bearings are provided directly in the seatings and whereby a second part of the housing is screwed onto the supporting structure, which part comprises the actual ring gear unit. It is also known to embed the main bearings as well as the ring gear unit in a separate housing which is provided on the supporting structure afterwards

It is also clear that, wind turbines of wind farms are facing frequent gearbox tooth failures in various subassemblies of the gearbox, viz the planet gears, sun gears, low-speed-shaft gears which constantly mesh with each other. When any of these gears start rupturing or undergoes progressive wear, metallic particles from the gearbox get crushed between the gears causing major damage to it. It is also known a system comprising a magnetic stick disposed inside the gearbox to where the metallic debris or chips that arise from the rupture of the gear teeth are attracted.

The above cited system has several drawbacks since the metallic particles concernd to the wear of the gear can only be detected by manual intervention. This makes necessary the stoppage of the operation of the wind turbine for checking the state of the magnetic stick. Moreover, this manual intervention could not be necessary depending on the amount of metallic particles adhered to the magnetic stick. These situations involve high costs to the wind farm operator.

The present invention solves all the above cited drawbacks by means of a gearbox metallic wear warning system and a related gearbox metallic wear warning method.

DESCRIPTION OF THE INVENTION

The present invention discloses a gearbox metallic wear warning system that minimizes the risk of severe incidents, preferably in the gear box of a wind turbine comprising said gearbox metallic particles detection system. The invention also concerns to the gearbox metallic wear warning method.

The gearbox metallic particles detection system comprises:

- a perforated metallic pipe defining a longitudinal direction corresponding to a longitudinal axis of the perforated metallic pipe;

- a set of magnets disposed inside the perforated metallic pipe, the set of magnets comprising at least two magnets; - a set of insulation elements disposed inside the perforated metallic pipe, the set of insulation elements comprising at least one insulation element, wherein at least one insulation element of the set of insulation elements is disposed between the at least two magnets of the set of magnets; and

- voltage measuring means configured to measure the voltage difference between the perforated metallic pipe and the set of magnets when the metallic particles are disposed between the perforated metallic pipe and the set of magnets.

Optionally, the gearbox metallic particles detection system further comprises an alarm device configured to be activated if the voltage difference between the perforated metallic pipe and the set of magnets when the metallic particles are disposed between the perforated metallic pipe and the set of magnets is greater than a predetermined threshold value.

Preferably, the at least two magnets of the set of magnets disposed inside the perforated metallic pipe are disposed along the longitudinal direction. Also preferably, the at least one insulation element of the set of insulation elements disposed inside the perforated metallic pipe is disposed along the longitudinal direction.

The invention also concerns to a wind turbine comprising at least a gearbox and a gearbox metallic particles detection system as described above.

The invention also concerns to a wind farm comprising at least a wind turbine as described above. The invention also concerns to a gearbox metallic particles detection method using a gearbox metallic particles detection comprising: - a perforated metallic pipe defining a longitudinal direction corresponding to a longitudinal axis of the perforated metallic pipe;

- a set of magnets disposed inside the perforated metallic pipe, the set of magnets comprising at least two magnets;

- a set of insulation elements disposed inside the perforated metallic pipe, the set of insulation elements comprising at least one insulation element, wherein at least one insulation element of the set of insulation elements is disposed between the at least two magnets of the set of magnets; and

- voltage measuring means configured to measure the voltage difference between the perforated metallic pipe and the set of magnets when the metallic particles are disposed between the perforated metallic pipe and the set of magnets;

wherein the method comprises a step of measuring the voltage difference between the perforated metallic pipe and the set of magnets when the metallic particles are disposed between the perforated metallic pipe and the set of magnets.

Optionally, the method further comprises a step of activating an alarm device if the voltage difference between the perforated metallic pipe and the set of magnets when the metallic particles are disposed between the perforated metallic pipe and the set of magnets is greater than a predetermined threshold value. So constituted, the gearbox metallic particles detection system and method of the invention present the following advantages:

- They ensure an improvement in the people’s safety: The risk of severe incidents is removed. Early warning allow to undertake immediate corrective actions if required.

- They allow getting better insurance policies: The severity of this kind of incidents drops dramatically. Thus its occurrence -and therefore its overall risk- is much lower, so the policies can be accordingly negotiated in better conditions.

- They improve the wind turbines generators (WTGs) availability due to an early detection of damages. In case of a metal wear, downtime is shorter and repair is faster as a result of a much less severe damage

(e.g., just replacing the high speed shaft assembly instead of the whole gearbox using cranes).

- They allow running the maintenance tasks with greater confidence:

Operation and maintenance (O&M) require corrective preventive inspection on periodic basis, but an automatic system for online warning -either caused by improper maintenance, materials defect or abnormal weather conditions- makes the maintenance more reliable.

DESCRIPTION OF THE DRAWINGS

To complement the description being made and in order to aid towards a better understanding of the characteristics of the invention, in accordance with a preferred example of practical embodiment thereof, a set of drawings is attached as an integral part of said description wherein, with illustrative and non-limiting character, the following has been represented:

Figure 1 shows a preferred embodiment of the gearbox metallic particles detection system of the present invention. Figure 2 shows a diagram of the gearbox metallic particles detection system shown in Figure 1 .

Figure 3 shows a view of the gearbox metallic particles detection system of the present invention disposed in a gearbox.

Figure 4 shows a view of the example with the gearbox metallic particles detection system of the present invention previously to be inserted into a beaker with oil simulating the lubricant and with iron filings of various sizes simulating the metallic particles disposed inside the gearbox.

Figure 5 shows a view of the example with the gearbox metallic particles detection system of the present invention after being inserted into a beaker with oil simulating the lubricant and with iron filings of various sizes simulating the metallic particles disposed inside the gearbox.

PREFERRED EMBODIMENT OF THE INVENTION

The present invention refers to a gearbox metallic particles detection system comprising:

- a perforated metallic pipe (1 ) defining a longitudinal direction corresponding to a longitudinal axis (7) of the perforated metallic pipe (1 );

- a set of magnets (2) disposed inside the perforated metallic pipe, the set of magnets (2) comprising at least two magnets (2);

- a set of insulation elements (3) disposed inside the perforated metallic pipe (1 ), the set of insulation elements (3) comprising at least one insulation element (3), wherein at least one insulation element (3) of the set of insulation elements (3) is disposed between the at least two magnets (2) of the set of magnets (2); and

- voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2).

Preferably, the perforated metallic pipe (1 ) is a perforated aluminium pipe (1 ). Also preferably, each one of the at least two magnets (2) of the set of magnets (2) disposed inside the perforated metallic pipe, is a disc shaped magnet (2), more preferably a disc shaped permanent magnet (2). Preferably, the at least one insulation element (3) of the set of insulation elements (3) disposed inside the perforated metallic pipe (1 ) is a disc shaped insulation element (3), more preferably a tape insulation element circumferentially disposed around the axis of the perforated metallic pipe (7).

Preferably, the gearbox metallic particles detection system further comprises an alarm device (not shown) configured to be activated if the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) is greater than a predetermined threshold value, being preferably the predetermined threshold value of 24V at 2,25A.

Preferably, the at least two magnets (2) of the set of magnets (2) disposed inside the perforated metallic pipe (1 ) are disposed along the longitudinal direction.

Also preferably, the at least one insulation element (3) of the set of insulation elements (3) disposed inside the perforated metallic pipe (1 ) is disposed along the longitudinal direction.

Preferably, the longitudinal axis (7) of the perforated metallic pipe (1 ) is a metallic longitudinal axis (7), more preferably an aluminium longitudinal axis (7).

Preferably, the voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) comprises a first wire (4) connected to the perforated metallic pipe (1 ) a second wire (5) connected to the set of magnets (2) and a device (6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2).

The invention also concerns to a wind turbine comprising at least a gearbox (20) and a gearbox metallic particles detection system as described above.

The invention also concerns to a wind farm comprising at least a wind turbine as described above. The invention also concerns to a gearbox metallic particles detection method using a gearbox metallic particles detection comprising:

- a perforated metallic pipe (1 ) defining a longitudinal direction corresponding to a longitudinal axis (7) of the perforated metallic pipe (1 ):

- a set of magnets (2) disposed inside the perforated metallic pipe, the set of magnets (2) comprising at least two magnets (2);

- a set of insulation elements (3) disposed inside the perforated metallic pipe (1 ), the set of insulation elements (3) comprising at least one insulation element (3), wherein at least one insulation element (3) of the set of insulation elements (3) is disposed between the at least two magnets (2) of the set of magnets (2); and

- voltage measuring means (4, 5, 6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2);

wherein the method comprises a step of measuring the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2).

Preferably, the method further comprises a step of activating an alarm device if the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are disposed between the perforated metallic pipe (1 ) and the set of magnets (2) is greater than a predetermined threshold value, being preferably the predetermined threshold value of 24V at 2,25A.

EXAMPLE

Several tests were carried out in order to attempt to know the accuracy and reliability of the gearbox metallic particles detection system and method of the present invention.

Figure 4 shows a view of an example with the gearbox metallic particles detection system of the present invention previously to be inserted into a beaker (30) with oil (31 ) simulating the lubricant and with iron filings of various sizes simulating the metallic particles (10) disposed inside the gearbox (20).

It is observed that the device (6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) indicates open loop circuit when the perforated metallic pipe (1 ), the set of magnets (2) and the set of insulation elements (3) are disposed out of the beaker (30) with oil (31 ) and metallic particles (10).

Figure 5 shows a view of the example shown in Figure 4 once the gearbox metallic particles detection system of the present invention has been inserted into the beaker (30) with oil (31 ) and metallic particles (10).

It is observed that the device (6) configured to measure the voltage difference between the perforated metallic pipe (1 ) and the set of magnets (2) when the metallic particles (10) are stuck to the perforated metallic pipe (1 ) and to the set of magnets (2), indicates a resistance value corresponding to circuit continuity, since the circuit has been closed by the metallic particles (10). li is observed that the bigger the metallic particles (10) are, the greater the resistance value is.