Basic Info.
Model NO.
VALENIAN-WFD800plus
Product Description
The VALENIAN-WFD800plus wind turbine fault testing platform is developed for simulating and testing various common mechanical and electrical faults in wind power generation systems. Parallel gearboxes, planetary gearboxes, rolling bearings, generator fault simulation, sensor faults, etc. can be conducted to enable researchers and technical developers to gain a deeper understanding of fault characteristics and impacts.University wind power test bench
The WFD800plus wind turbine fault testing platform is developed for simulating and testing various common mechanical and electrical faults in wind power generation systems. Parallel gearboxes, planetary gearboxes, rolling bearings, generator fault simulation, sensor faults, etc. can be conducted to enable researchers and technical developers to gain a deeper understanding of fault characteristics and impacts.
Research on Fault Diagnosis: Providing an experimental platform for the study of fault diagnosis technology, developing and verifying fault diagnosis algorithms and methods by collecting various data from the test bench under fault conditions, such as electrical signals, mechanical vibration signals, temperature signals, etc.
Maintenance training: It can be used to train wind power operation and maintenance personnel, allowing them to practice operations in simulated fault environments, familiarize themselves with fault diagnosis and maintenance processes, improve maintenance skills and the ability to respond to actual faults.
Optimization design: By simulating different fault situations, analyzing the weak links of the system, providing a basis for the optimization design of wind power generation systems, improving the system's structure and control strategies, and enhancing the system's reliability and fault tolerance.
Teaching demonstration: In teaching, help students intuitively understand the working principle, fault generation mechanism, and handling methods of wind power generation systems, enhance their practical ability and mastery of professional knowledge.
function
Conduct simulation experiments on common rotor mechanical faults, such as shaft misalignment, rotor imbalance, and loose mechanical foundations.
An additional optional laser centering device is used for precise axis alignment and alignment testing.
Research on the Failure Mechanism of Parallel Shaft Gearboxes: Different Failure Forms of Straight Teeth, such as pitting, wear, cracks, and breakage
Common faults such as missing teeth and missing teeth can be customized according to specific needs.
Research on Rolling Bearing Faults: Different forms of faults in the internal bearings and supporting bearings of gearboxes, such as bearing inner ring faults, bearing outer ring faults, bearing cage faults, bearing rolling element faults, and comprehensive bearing faults.
Research on planetary gearbox faults: sun gear, planetary gear, large ring gear, fault types, missing teeth, wear, broken teeth, cracks;
Generator fault research: In addition, different types of faulty generators can be selected and combined with current and voltage sensors to study generator rotor, generator rotor imbalance faults, generator bearing faults, generator rotor bar breakage faults, generator turn to turn short circuit faults
Standard faulty parts:
The high-speed small gear at the output end has fault types such as pitting, cracking, tooth breakage, and missing teeth.
Support bearing inner ring failure, bearing outer ring failure, bearing cage failure, bearing rolling element failure, and comprehensive bearing failure.
Additional optional faulty parts:
Generator faults: Generator rotor imbalance fault, generator bearing fault, generator rotor bar breakage fault, generator turn to turn short circuit fault, generator voltage imbalance phase loss fault.
Internal bearing faults in the gearbox: inner ring fault, outer ring fault, bearing cage fault, rolling element fault, and comprehensive bearing fault.
3: The main components of the experimental platform
The test bench system mainly consists of a cast iron platform, a reduction drive motor, a planetary gearbox system, a parallel axis gearbox system, a dynamic torque sensor system, a torque load system, a generator (installed interchangeably with the torque load system), a protection system, a test bench control system, a double support bearing unit, an adjustable resistance energy consumption system, a simulated blade wind tower, etc. In addition, it is important that the magnetic powder load brake can be connected to the gear transmission system, so that the output torque of the magnetic brake can be freely controlled through current regulation.
4: Introduction to the main components and structure of the experimental platform
4.1 Platform Base Plate
1) Material: Cast iron platform with T-shaped groove;
2) Size: 2080mm * 880mm * 145mm
3) Roughness: Ra: 3.2
4.2 Drive motor
1. Group drive motor: three-phase asynchronous motor, touch screen operation control.
2. Rated power: 1.1KW.
3. Rated speed: 19rpm/50Hz, 23rpm/60Hz.
4. Reduction ratio: 80:1.
5. Rated torque: Output torque of 45.7kgf · m/50Hz, 42.5kkgf · m/60Hz.
6. Rated current: 5.0A/220V; 2.89A/380V.
4.3 First stage planetary gearbox reducer
1. Reduction ratio: 5:1.
2. Rated output torque: 420NM.
3. Moment of inertia: 4.93kgcm ².
4. Rated input speed: 2500min, maximum input speed: 4500min.
5. Maximum output radial force: Fr=4900N, maximum output axial force: Fa=3700N.
6. Noise level of 70dB, lubrication method using grease.
7. Protection level IP65.
Optional types of faulty planetary gears are available: cracks, wear, missing teeth, and broken teeth.
4.4 Two stage parallel gearbox
1. Gear material: 20CrMnTi.
2. Modulus: 2.
3. The number of teeth is Z1=95, Z2=29, Z3=56, Z4=23.
4. Speed ratio: 1:7.976.
5. Internal support bearing, deep groove ball type, model 600860056204.
6. Shaft diameters of 40mm, 25mm, 20mm,
7. Cast iron material, oil splash lubrication.
8. Safety protection: Equipped with a transparent acrylic observation protective cover.
9. Gearbox faulty bearings can be selected, such as bearing outer rings, bearing inner rings, bearing rolling elements, bearing retainers, and bearing comprehensive faults. The type and severity of faults can be customized.
10. The types of faults that small teeth can simulate include broken teeth, wear, missing teeth, and crack faults.
4.5 Dynamic torque sensor system
1. It can display real-time operating parameters such as torque and speed;
2. Range: ± 50N. m.
3. Accuracy: 0.5% F · S.
4. Output mode: Voltage is ± 5V or 0-5V, or RS485., or 4-20mA output mode.
5. Speed output: 60 pulses per revolution.
6. Nonlinear, 0.1% F.S.
7. Speed range ≤ 10000RPM.
4.6 Shaft assembly
1. Supported by bearing seat, normal bearing, faulty bearing, and dynamic balancing rotor disc.
2. Supporting bearing seat: including UCPH205 healthy deep groove ball bearings, made of 45 steel, with vibration sensor installation threaded holes (M6).
4. Faulty bearing seat: It includes five types of faulty bearings, which can be replaced with different types of faulty bearings such as inner ring fault, outer ring fault, cage fault, ball bearing fault, and comprehensive fault. Different bearing fault severity levels can also be customized.
5. Rotor: Aluminum, two pieces, with 30 holes for mass block installation, distributed at 12 ° intervals, M5.
4.7 Torque Load Simulation
1. Load form: Magnetic powder brake.
2. Braking torque: 10N. m.
3. Rated working voltage: 24V, current 0.6A.
4. Maximum speed: 1500RPM.
5. Slip power: 0.12/0.8.
6. Cooling method: Natural cooling.
4.8 Permanent magnet generator:
1. Generator power: 3KW,
2. Rated output voltage: 380V/220V,
3. Output mode: three-phase four wire system,
4. Frequency: 50Hz,
5. Rated speed: 500RPM,
6. Generator rotor body form: permanent magnet.
Additional optional generator faulty parts:
Generator faults: Generator rotor imbalance fault, generator bearing fault, generator rotor bar breakage fault, generator turn to turn short circuit fault, generator voltage imbalance phase loss fault.
4.9 Tower and impeller hub components
Adopting independent motor drive and modular wind turbine tower device, the use is more vivid and vivid
1. The overall height is 2.02m,
2. Number of leaves, three,
3. Material, stainless steel
4. Blade length, 0.2 meters,
5. The working voltage of the driving motor is 220V
6. Control method: Touch screen control for start and stop.
4.10 Energy Consumption Load System
Passive load devices use internal resistor groups to consume power generated by the generator. They are equipped with pure resistive loads that can meet the requirements of 0.5KW-3KW, 0.5KW+0.5KW+1KW+1KW, and can be adjusted to simulate various power loads in any combination, meeting the needs of generator full load detection. Using an LCD panel can simultaneously display parameters such as voltage, current, frequency, etc.
4.11 Test bench control system system
1.10-inch touchscreen visual human-machine interface;
2. Test bench PLC intelligent start stop control, speed and load control.
3. Real time display on touch screen: Visualize and adjust various testing conditions such as speed, torque, output frequency, output voltage, IGBT temperature, bus voltage, output power, output current, and output torque settings. Simultaneously equipped with an emergency stop button to immediately shut down in case of emergency;
4. The control cabinet is equipped with foot rollers for easy movement;
4.12 Protection System
At the rotor rotation point, the protective cover is made of 1.5mm thick yellow steel plate.
The console has an emergency stop button that can be used to stop the device in case of any abnormalities.
4.13 Requirements for Equipment Usage Conditions
1. Environmental temperature: -30~70 ºC (storage), -10~50 ºC (use).
2. Ground wire requirements: Install standard ground wires on site.
3. Power supply: three-phase 380V ± 10%, 50Hz, power 4kW.
4. No dust or corrosive substances.
4.14 Testing System Measurement Point Location
1) Distribution of measurement points;
Test bench measuring points (the platform is actually a T-shaped slot cast iron platform)
The driving deceleration motor can flexibly arrange acceleration sensors to measure vibration values.
The first level planetary gearbox can flexibly arrange acceleration sensors to measure vibration values.
The parallel axis gearbox can flexibly arrange acceleration sensors to measure vibration values, and noise sensors to measure noise signalsSupporting bearings can be flexibly arranged with acceleration sensors to measure vibration values and noise sensors to measure noise signals.
The permanent magnet generator can flexibly arrange acceleration sensors to measure vibration values, and three-phase current and voltage sensors to measure current and voltage signals.
5: Schematic diagram of WFD800plus wind turbine fault test bench
Schematic diagram of WFD800plus wind turbine fault testing platform structure
6: Technical parameters of WFD800plus wind turbine fault test bench
Number Project Technical Parameters Remarks
The basic component unit consists of cast iron platform, reduction drive motor, planetary gearbox system, parallel shaft gearbox system, dynamic torque sensor system, torque load system, generator (installed interchangeably with rotor bearing torque load system), protection system, test bench control system, double support bearing unit, adjustable resistance energy consumption system, simulated blade wind tower, etc.
Process control parameter visualization operation mode is used to display and adjust various test conditions such as speed, torque, output frequency, output voltage, IGBT temperature, bus voltage, output power, output current, and output torque settings. Simultaneously equipped with an emergency stop button to immediately shut down in case of emergency.
3. Visual operation screen size, 10. Touch panel, four wire resistive touch screen, resistant to voltage shock, AC1000V,10mA, Less than 1 minute (between signal and ground), anti-interference ability, interference voltage: 1500Vp-p, pulse period: 1us, duration: 1 minute, insulation resistance, DC500V, above 10M Ω (between signal and ground).
4 PLC program capacity 256KB, 8 input/output points, communication protocol, standard MODBUSASCII/RTU communication, communication port, free-form communication, 1 channel 232, 1 channel 485, 1 USB communication port.
5 Analog Input Module Analog Power Supply, DC24V ± 10%, 150mA, Conversion Speed, 2ms/ch, Input Resolution, 1/16383 (14Bit), Output Resolution, 1/4095 (12Bit) AD Filter Coefficient 0~254, Comprehensive Accuracy ± 1%, AD Channel with Short Circuit, Open Circuit, and Over Range Detection Functions.
6-phase asynchronous gear drive motor with a motor power of 1.1KW, output speed of 19rpm/50Hz, 23rpm/60Hz, reduction ratio of 80:1, output torque of 45.7kgf · m/50Hz, 42.5kgf · m/60Hz.
Variable frequency drive frequency range: 0-599Hz, rated input: three-phase 380V, 50/60Hz, rated output: 3PH 5.5KW.
8. Plum blossom coupling with shock-absorbing pad.
9. The supporting bearing seat includes UCPH205 healthy deep groove ball bearings, made of 45 steel, with threaded holes (M6) for installing vibration sensors. Faulty bearing seat: includes five types of faulty bearings, which can be replaced for inner ring fault, outer ring fault, cage fault, ball bearing fault, and comprehensive fault.
10 aluminum rotor disks, two, with 30 holes for mass block installation, distributed at 12 ° intervals, M5.
The reduction ratio of the planetary gearbox is 5:1, the rated output torque is 420NM, the moment of inertia is 4.93kgcm ², the noise level is 70dB, the lubrication method is grease, and the protection level is IP65. Rated input speed: 2500min, maximum input speed: 4500min, maximum output radial force: Fr=4900N, maximum output axial force: Fa=3700N.
12 Two stage parallel gearbox module=2 teeth Z1=95, Z2=29, Z3=56, Z4=23. Speed ratio: 7.976:1, internal support bearing, 600860056204, shaft diameter 40mm, 25mm, 20mm, cast iron material, oil splash lubrication.
13. Dynamic torque sensor of torque tachometer: range 0-50N. M, speed range ≤ 10000RPM, non-linear, 0.1% F.S., output voltage of ± 5V or 0-5V, or RS485, or 4-20mA output mode, can directly display speed and torque in real time.
14 permanent magnet generator with a power of 3KW, output rated voltage of 380V/220V, output mode, three-phase four wire system, frequency of 50Hz, rated speed of 500RPM, generator rotor form, permanent magnet.
15 magnetic powder brake rated torque, 10N. M, voltage 24V, current 0.6A, maximum speed 1500RPM, slip power, 0.12/0.8, cooling method, natural cooling.
The input signal of the 16-year-old power amplifier is adjusted by an external 10K potentiometer or input DC0-5V, DC0-10V, DC0-20mA to control the output. The voltage is DC24V or 36V, and the current is DC0-1A, 0-2A, 0-3A. The characteristics are that the output current is proportional to the input signal and has short-circuit protection function.
The overall height of the 17 meter wind tower and impeller hub assembly is 2.02m, with three blades, three materials, stainless steel, blade length, 0.2 meters, and a driving motor working voltage of 220V.
18 rated voltage of the power consumption load system, AC380V, Power grading, 0.5KW+0.5KW+1KW+1KW, display content, voltage/current/power/frequency/power factor, protection function, over temperature alarm, one key unloading, short circuit protection, overcurrent protection.
The size of the 19 testing platform is 2080mm * 880mm * 145mm, with precision machined cast iron T-shaped groove installation base plate, roughness Ra: 3.2. Rotating Machinery Engineering Application Testing Platform
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20 power input 380VAC, three-phase, 50/60 Hz.
