Research On Structural Design Method Of Megawatt Wind Turbine Gearbox And Software Development

Governance of haze and adjustment of energy structure promote the wind power industry to achieve further development in our country. High-power wind turbine gearbox can improve the utilization rate of wind energy and reduce the area covered by wind farm. Thus, increasing the power of single machine is a direction of future development of wind turbine. With the power of single machine increasing, the size and weight of parts obtained by the existing structural design methods, which are dominated by experience and analogy, are bound to rise. Therefore, the structural optimization design method of megawatt wind turbine gearbox is proposed by studying the structural optimization theory, and the structural design processing automation software is developed based on the method and requirements of the project in this paper. The software can realize automation of structural optimization design, improve design efficiency, enhance the strength of corporate R&D. Specific contents are as follows:(1) Taking structural characteristics of the wind turbine gearbox parts into account, the structural optimization theory was introduced into structural design of wind turbine gearbox, and the structural optimization design method of megawatt wind turbine gearbox is proposed which contains model design, structural concept design, structural detailed design, structural analysis and evaluation. Digital expression of initial geometric model is studied in model design. A conceptual structural design method is established through the analysis of various parameters influence on the optimization results. Structural process characteristics are commonly used for wind turbine gearbox are considered and the response surface method is used for size optimization in structural detailed design. In order to complete checking the final structural plan, both analysis principles and evaluation indexes are studied in the structural performance analysis and evaluation.(2) The structural design processing automation software of megawatt wind turbine gearbox is developed based on the method. According to the requests of the project, the requirements and development goals of the software are clarified, and the XAF architecture and HyperWorks secondary development tools used in software development are introduced in detail. The principle of the XAF interface development, the key code of the background program and the automatic generation of reports and so on are discussed at length. The CAE analysis module based on HyperWorks is introduced through flow chart and panel.(3) The structural optimization of a 6MW power-split wind turbine gearbox is carried out by using the automation software. In the example, the initial geometric model of the box is determined by the model design module, and the CAE analysis module which is developed by secondary development is called for the topology optimization design. The concept structural model is obtained by the results of the topology optimization. Size optimization makes the key size to achieve the best combination, and the final model is determined by the process design and performance analysis and evaluation.Application example proves the feasibility of method and the operation of software, and the software can improve the structural design efficiency by 90%. The contents of this paper provides new design ideas for the structural design of the wind turbine gearbox, and has a certain reference value to develop similar process automation software for enterprise.