Abstract
Brake pads of disc brake play an important role in the stable braking process of a large-megawatt wind turbine. There is always vibration, screaming, and severe nonuniform wear under the effect of both retardation pressure and friction. To solve these issues, this article aims to find a new structure of the brake pads to improve brake performance. A multiobjective structure topology optimization method considering thermal-structural coupling and brake vibration is carried out in this article. Based on topology optimization method of Solid Isotropic Microstructures with Penalization (SIMP), the compromise planning theory is applied to meet the stiffness requirement and vibration performance of brake pads. Structure of brake pads is optimized, and both the stiffness and vibration performance of brake pads are also improved. The disadvantages of single-objective optimization are avoided. Thermal-structural coupling analysis is tested with the actual working conditions. The results show that the new structure meets the stiffness requirement and improves the vibration performance well for the large-megawatt wind turbine. The effectiveness of the proposed method has been proved by the whole optimization process.
Highlights
Brake pads are an important component of the brake system for large-megawatt wind turbine’s working stability
Model of the brake pads needs to be simplified before the analysis of topology optimization considering thermal-structural coupling
The result shows that both the third and the fourth modes are far away from the frequency of braking screaming, which means the optimized brake pads meet the requirement of the dynamic objective
Summary
Brake pads are an important component of the brake system for large-megawatt wind turbine’s working stability. The brake pad-disc contact generates large amounts of heat with retardation pressure and friction. Contact discontinuities causing uneven distribution of contact surface temperature lead to thermal deformation of the disc, which directly affects the contact state and contact stress and further impacts the input intensity of friction heat This coupling behavior leads to the thermoelastic instability (TEI) and causes the brake vibration and noise [2]. Based on Sha’s result, Zhang et al considered the thermal-structural coupling, and the optimized brake pads showed that much more material is needed to be maintained to conduct the heat generated in the braking process. In order to find the frequency influence on the structure design of brake pads, this article develops a multiobjective structure topology optimization method considering thermal-structural coupling and brake vibration. Braking torque M (Nm) 3500 method proposed in this article offers some insights into the optimization of other similar structures
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