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產(chan)品名(ming)稱：風電制動器摩(mo)擦(ca)片
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QP12.7氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)鉗盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)架和氣(qi)(qi)缸兩大部(bu)分(fen)組成(cheng)風電(dian)(dian)偏航制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)氣(qi)(qi)缸1通入壓(ya)(ya)力氣(qi)(qi)時PDC5氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)，活塞桿5在氣(qi)(qi)壓(ya)(ya)作(zuo)(zuo)用下(xia)迅速(su)PDB19氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)臂在復位彈簧4PDC5氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)PDE10氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)電(dian)(dian)磁(ci)失效(xiao)保護盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)防風制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)焦作(zuo)(zuo)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)股(gu)份有限(xian)公司氣(qi)(qi)動(dong)(dong)(dong)(dong)(dong)(dong)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)盤式(shi)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)剎車片(pian)風電(dian)(dian)制(zhi)(zhi)動(dong)(dong)(dong)(dong)(dong)(dong)器(qi)(qi)(qi)(qi)摩擦片(pian)
產品特性Product characteristics
風電制動器摩擦片
電動液壓夾軌器結構(gou)特(te)點
1.夾軌器結構緊(jin)湊,造(zao)型美(mei)觀(guan).
北極(ji)星(xing)風力發(fa)(fa)電(dian)(dian)網訊:風機通過自動偏(pian)航(hang)(hang)(hang)找到主(zhu)風向(xiang)，在運(yun)行過程中偏(pian)航(hang)(hang)(hang)制(zhi)動比較頻繁，如(ru)果偏(pian)航(hang)(hang)(hang)制(zhi)動盤(pan)損(sun)傷和(he)摩擦(ca)(ca)片磨損(sun)會造成偏(pian)航(hang)(hang)(hang)過程中發(fa)(fa)生(sheng)振(zhen)動異響(xiang)，并(bing)引發(fa)(fa)機艙旋轉超速或偏(pian)航(hang)(hang)(hang)、液壓(ya)站(zhan)故障，不但(dan)降(jiang)低了(le)機組可利用(yong)(yong)率和(he)摩擦(ca)(ca)片的(de)使用(yong)(yong)壽命，而且造成了(le)偏(pian)航(hang)(hang)(hang)剎車(che)盤(pan)結構(gou)件疲勞從而影響(xiang)了(le)機組整體的(de)使用(yong)(yong)壽命。因(yin)此，分析(xi)3MW風力發(fa)(fa)電(dian)(dian)機組偏(pian)航(hang)(hang)(hang)偏(pian)航(hang)(hang)(hang)制(zhi)動盤(pan)損(sun)傷和(he)摩擦(ca)(ca)片磨損(sun)的(de)原因(yin)并(bing)提出解決方法(fa)，是風機運(yun)維工作迫切需要解決的(de)問題。
一、風力發電機組偏航系統的工作原理及作用風電制動器摩擦片
3MW風(feng)(feng)(feng)力發電(dian)機(ji)組采用主(zhu)動偏航對(dui)風(feng)(feng)(feng)方(fang)式，超(chao)聲(sheng)波風(feng)(feng)(feng)速儀(yi)的(de)(de)通過(guo)風(feng)(feng)(feng)穿過(guo)腔體時所引起(qi)的(de)(de)信(xin)號(hao)相變來測(ce)量氣流(liu)運動反映出風(feng)(feng)(feng)機(ji)與主(zhu)風(feng)(feng)(feng)向(xiang)之間的(de)(de)偏離程度，機(ji)組在運行時根據超(chao)聲(sheng)波風(feng)(feng)(feng)速儀(yi)檢(jian)測(ce)的(de)(de)風(feng)(feng)(feng)向(xiang)與機(ji)艙方(fang)向(xiang)的(de)(de)夾(jia)角決定(ding)風(feng)(feng)(feng)機(ji)是(shi)否偏航。當風(feng)(feng)(feng)速持續發生變化時，主(zhu)控(kong)PLC根據超(chao)聲(sheng)波風(feng)(feng)(feng)速儀(yi)傳遞的(de)(de)信(xin)號(hao)控(kong)制偏航驅動裝置使機(ji)艙旋轉對(dui)準主(zhu)風(feng)(feng)(feng)向(xiang)。
在(zai)機(ji)組偏(pian)(pian)航(hang)(hang)時，安裝(zhuang)在(zai)機(ji)艙上(shang)的(de)偏(pian)(pian)航(hang)(hang)制動(dong)(dong)器加載(zai)有(you)主液壓站10%的(de)剎車載(zai)荷（25bar-15bar的(de)冗余壓力），使得偏(pian)(pian)航(hang)(hang)過程中始終有(you)阻(zu)(zu)尼存在(zai)，保證(zheng)機(ji)艙平(ping)穩(wen)(wen)轉動(dong)(dong)。偏(pian)(pian)航(hang)(hang)制動(dong)(dong)器采用常閉式結構的(de)液壓驅動(dong)(dong)方式，即靜止時偏(pian)(pian)航(hang)(hang)制動(dong)(dong)器將機(ji)艙制動(dong)(dong)鎖定，在(zai)需要偏(pian)(pian)航(hang)(hang)時，偏(pian)(pian)航(hang)(hang)制動(dong)(dong)器打開且保持(chi)一定的(de)冗余壓力，使機(ji)艙在(zai)阻(zu)(zu)尼作(zuo)用下平(ping)穩(wen)(wen)偏(pian)(pian)航(hang)(hang)。機(ji)組根據偏(pian)(pian)航(hang)(hang)轉動(dong)(dong)的(de)制動(dong)(dong)載(zai)荷扭矩安裝(zhuang)有(you)7臺偏(pian)(pian)航(hang)(hang)制動(dong)(dong)器。
(二）偏航系統作用
風力(li)發電機組機組偏(pian)航(hang)主要在以下幾點情況下出(chu)現:
1.風向發生(sheng)變化時，機組主動(dong)尋(xun)找主風向而自動(dong)偏航(hang)對風。
2.機組(zu)朝著一個方向(xiang)偏(pian)航到(dao)設定角度以后，為了(le)使機組(zu)懸垂部分的電纜(lan)不至于過度扭絞(jiao)而自動反方向(xiang)偏(pian)航解纜(lan)。
3.強制(zhi)偏航，當電纜(lan)的扭(niu)絞程度威(wei)脅(xie)到機組(zu)安(an)全(quan)運行時會(hui)觸發扭(niu)纜(lan)保護裝置(zhi)，使機組(zu)停止旋轉或保持設備(bei)停車(che)狀態，此時若恢復機組(zu)運行，必須手(shou)動強制(zhi)偏航使其解纜(lan)。
二、偏航制動盤損傷和摩擦片磨損原因分析
風機在偏航過(guo)程中(zhong)因偏航制動盤損傷(shang)和摩(mo)擦片(pian)磨損造(zao)成(cheng)塔筒振動峰值較高(gao)且偏航運動產生(sheng)噪聲，不(bu)利于風機安全運行，結合偏航工(gong)作原理及實際工(gong)作中(zhong)對故障(zhang)的處(chu)理，從以下幾個(ge)方面(mian)分析。
（一）偏航制動器安裝問題
液壓鉗盤式制(zhi)動器為機(ji)艙提(ti)供必要的(de)制(zhi)動扭矩，以保障機(ji)組的(de)安全運行，在機(ji)組偏航(hang)時制(zhi)動器提(ti)供的(de)阻尼力矩應(ying)保持平穩(wen)，,制(zhi)動摩擦片(pian)與制(zhi)動盤的(de)貼合面(mian)積應(ying)不小于(yu)設(she)計面(mian)積的(de)50%，閉合時摩擦片(pian)周(zhou)邊與制(zhi)動鉗體(ti)的(de)配合間隙任一處應(ying)不大(da)于(yu)0.5mm。
偏(pian)航制動器在工作(zuo)時，液壓(ya)油進(jin)入缸體，在油壓(ya)的(de)作(zuo)用下(xia)兩個缸體內(nei)的(de)柱(zhu)塞推動摩擦(ca)片做相(xiang)向運動，摩擦(ca)片在制動力矩下(xia)卡住(zhu)剎(cha)車(che)盤，使(shi)機艙的(de)偏(pian)轉運動停止，從而實現(xian)制動作(zuo)用。
偏航摩擦片在安裝過程中在制動器與基座之間加裝有間隙調整裝置（調整墊片)，目的是調整摩擦片與偏航盤之間的間隙，但是當裝配間隙發生變化后，導致制動器摩擦片與制動盤安裝不平行，或者鉗體與摩擦片貼合緊密，使得局部摩擦力增大。在更換安裝摩擦片后未進行間隙調整，導致上下摩擦片卡澀或者竄動，偏航時摩擦片對制動盤的軸向壓力不相等。由于每臺機組上制動器的數量有7個，如果每個摩擦片與制動盤的間距不*，摩擦力矩不均勻，偏航運動摩擦過程中制動盤上的多個受力點受力情況不*，每個接觸點的摩擦都是不連續的，而是點與點之間相互相互交替的過程，這種交替運動使摩擦過程中伴有振動，也是造成偏航制動盤損傷和摩擦片磨損明顯的摩擦運動。
（二）摩(mo)擦材料(liao)的性(xing)能及摩(mo)擦過程分(fen)析
風機偏(pian)(pian)航(hang)制動(dong)(dong)(dong)器技術參數里(li)規定(ding)摩(mo)(mo)擦(ca)材(cai)(cai)料的(de)摩(mo)(mo)擦(ca)系(xi)數為0.4，如果摩(mo)(mo)擦(ca)系(xi)數大于0.4，對制動(dong)(dong)(dong)盤(pan)(pan)的(de)磨損(sun)量會(hui)增大，進而導(dao)(dao)致(zhi)偏(pian)(pian)航(hang)過程中熱量增大，熱量將導(dao)(dao)致(zhi)摩(mo)(mo)擦(ca)材(cai)(cai)料表面(mian)燒(shao)結，表面(mian)材(cai)(cai)質變(bian)硬，摩(mo)(mo)擦(ca)系(xi)數降(jiang)低。如果摩(mo)(mo)擦(ca)系(xi)數小于0.4，偏(pian)(pian)航(hang)時阻(zu)尼力矩與制動(dong)(dong)(dong)力矩減小，將影響(xiang)機組偏(pian)(pian)航(hang)過程中的(de)準(zhun)確定(ding)位。那么在多次摩(mo)(mo)擦(ca)后的(de)壓力和溫度(du)雙重作用下，制動(dong)(dong)(dong)盤(pan)(pan)和摩(mo)(mo)擦(ca)片比壓較高的(de)接觸面(mian)出現(xian)硬化(hua)、碳化(hua)等異化(hua)現(xian)象，摩(mo)(mo)擦(ca)系(xi)數下降(jiang)過快(kuai)，但(dan)是此時偏(pian)(pian)航(hang)制動(dong)(dong)(dong)器因液壓系(xi)統壓力未(wei)明顯變(bian)化(hua)，偏(pian)(pian)航(hang)時會(hui)產生(sheng)(sheng)制動(dong)(dong)(dong)打(da)滑(hua)引(yin)起偏(pian)(pian)航(hang)摩(mo)(mo)擦(ca)片磨損(sun)，加(jia)之制動(dong)(dong)(dong)盤(pan)(pan)接觸面(mian)受壓不(bu)同產生(sheng)(sheng)共振(zhen)，共振(zhen)產生(sheng)(sheng)的(de)作用力加(jia)劇偏(pian)(pian)航(hang)制動(dong)(dong)(dong)盤(pan)(pan)磨損(sun)。
摩(mo)擦(ca)(ca)(ca)材料(liao)對(dui)載(zai)荷、滑動速度及環境溫度等因素有較高要求(qiu)。由于(yu)偏(pian)航(hang)系統處于(yu)非封(feng)閉的(de)環境里，氣(qi)候條件(jian)的(de)變(bian)化以及環境因素的(de)變(bian)化（摩(mo)擦(ca)(ca)(ca)熱量增加）會引起摩(mo)擦(ca)(ca)(ca)副的(de)摩(mo)擦(ca)(ca)(ca)系數發生波(bo)動，摩(mo)擦(ca)(ca)(ca)的(de)不穩定性導(dao)致(zhi)偏(pian)航(hang)時制動盤在摩(mo)擦(ca)(ca)(ca)力的(de)作用下產生振動，從(cong)而造成(cheng)制動盤損(sun)傷和摩(mo)擦(ca)(ca)(ca)片磨損(sun)。
偏航制動器應保證在較寬的制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)初速度(du)及較(jiao)(jiao)小的(de)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)比(bi)(bi)壓(ya)下(xia)，獲得足夠的(de)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)力矩(ju)穩定性。但(dan)實際上往往制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)盤(pan)，摩(mo)(mo)擦(ca)(ca)材(cai)料的(de)平面度(du)，平行(xing)度(du)控制(zhi)(zhi)(zhi)并不能達到(dao)標(biao)準(zhun)要求，造(zao)成(cheng)摩(mo)(mo)擦(ca)(ca)面結(jie)合(he)不均勻。偏(pian)航(hang)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)器摩(mo)(mo)擦(ca)(ca)片(pian)材(cai)料均采用樹脂聚合(he)物為主的(de)復合(he)材(cai)料，該材(cai)質的(de)剎(cha)(cha)車(che)片(pian)熱(re)衰(shuai)減溫度(du)，承受(shou)比(bi)(bi)壓(ya)相對較(jiao)(jiao)低，機組在(zai)長期運行(xing)過程中(zhong)，摩(mo)(mo)擦(ca)(ca)片(pian)與(yu)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)盤(pan)相互摩(mo)(mo)擦(ca)(ca)產生(sheng)摩(mo)(mo)擦(ca)(ca)殘(can)留物（碳粉），碳粉會附著(zhu)在(zai)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)盤(pan)和(he)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)器剎(cha)(cha)車(che)片(pian)之間(jian)。隨著(zhu)碳粉的(de)積累(lei)量較(jiao)(jiao)多，碳粉在(zai)摩(mo)(mo)擦(ca)(ca)片(pian)與(yu)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)盤(pan)之間(jian)受(shou)到(dao)壓(ya)力和(he)摩(mo)(mo)擦(ca)(ca)熱(re)的(de)作用，當制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)產生(sheng)的(de)熱(re)量超過了(le)剎(cha)(cha)車(che)片(pian)的(de)熱(re)衰(shuai)減溫度(du)，這些殘(can)留物就會在(zai)剎(cha)(cha)車(che)片(pian)表面形成(cheng)一(yi)層燒饒(rao)層（即脆化光亮的(de)釉光層），釉層是摩(mo)(mo)擦(ca)(ca)片(pian)和(he)制(zhi)(zhi)(zhi)動(dong)(dong)(dong)(dong)盤(pan)之間(jian)的(de)作用效果發生(sheng)變(bian)化，當釉層積累(lei)越厚，摩(mo)(mo)擦(ca)(ca)系數(shu)波動(dong)(dong)(dong)(dong)，在(zai)阻尼(ni)作用下(xia)產生(sheng)的(de)振動(dong)(dong)(dong)(dong)頻率與(yu)與(yu)機組的(de)固(gu)有頻率發生(sheng)共振時(shi)，導(dao)致偏(pian)航(hang)過程中(zhong)摩(mo)(mo)擦(ca)(ca)片(pian)不均勻磨損。
