大型水轮机组推力轴承材料与结构及其润滑性能研究进展

杨子毅; 汤正阳; 薛炳; 李湧博; 李虎; 向艾军; 王优强

doi:10.16490/j.cnki.issn.1001-3660.2025.20.003

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表面技术 ›› 2025, Vol. 54 ›› Issue (20) : 28-43. DOI: 10.16490/j.cnki.issn.1001-3660.2025.20.003

研究综述

大型水轮机组推力轴承材料与结构及其润滑性能研究进展

杨子毅^1a, 汤正阳^2,3, 薛炳^2,3, 李湧博^2,3, 李虎², 向艾军^2,3, 王优强^1a,1b,*

作者信息 +

Research Progress on Materials, Structures, and Lubrication Performance of Thrust Bearings in Large Hydro-turbine Units

YANG Ziyi^1a, TANG Zhengyang^2,3, XUE Bing^2,3, LI Yongbo^2,3, LI Hu², XIANG Aijun^2,3, WANG Youqiang^1a,1b,*

Author information +

文章历史 +

摘要

随着中国的能源结构向绿色低碳转型,水电作为清洁能源的重要组成部分,其核心设备水轮机的可靠性和效率备受关注。推力轴承作为水轮机组中承受轴向载荷的关键部件,其润滑性能直接影响机组的运行稳定性。系统综述了大型水轮机组推力轴承及其润滑性能的研究进展,介绍了推力轴承及其静压顶升装置的结构特点,分析了刚性支柱螺栓支撑、弹簧簇支撑、弹性油箱支撑、弹性橡胶垫支撑、弹性圆盘支撑和弹性柱销簇支撑等类型推力轴承的优缺点及其适用工况;对比了巴氏合金、聚四氟乙烯（PTFE）和聚醚醚酮（PEEK）等推力轴瓦材料的性能,并探讨了其在力学性能、热学特性及润滑性能方面的优劣。此外,详细阐述了基于Reynolds方程的热流体动力润滑（THD）和热弹性流体动力润滑（TEHD）分析方法,以及基于计算流体力学（CFD）的润滑特性研究进展,并总结了这些方法在推力轴承润滑特性研究中的应用现状及局限性。最后,从支撑结构优化设计、新型复合材料研发、多尺度润滑机理研究和润滑系统智能运维等角度,对未来大型水轮机组推力轴承的发展方向进行了展望。

Abstract

The global transition towards green and low-carbon energy systems has elevated hydropower as a critical clean energy source, placing significant emphasis on the reliability and efficiency of hydro-turbines. As the key component bearing the entire axial load (including rotor weight and hydraulic thrust) in vertical hydro-turbine units, the lubrication performance of thrust bearings directly dictates operational stability and longevity. The work aims to provide a comprehensive review of the research progress on thrust bearings and their lubrication characteristics in large hydro-turbine units, focusing on structural design, material selection, and lubrication analysis methodologies.
The structural characteristics of thrust bearings are systematically examined, focusing on six primary support designs and their operational suitability. Rigid pillar bolt supports, though simple, require extreme manufacturing precision and lack adaptability, making them unsuitable for high-load applications. Spring cluster supports excel in load distribution and thermal performance but demand high-precision manufacturing. Elastic oil tank systems offer superior self-balancing through interconnected pressurized oil chambers, yet their complexity and potential leakage risk limit widespread adoption. Elastic rubber pad supports provide cost-effective solutions for low-load scenarios with inherent insulation benefits, but their limited load capacity and fatigue susceptibility restrict heavy-duty use. Elastic disc supports feature compact designs with uniform load distribution, though their spherical contact surfaces may induce stress concentrations. The most advanced solution—elastic pin cluster-supported double-layer pads—effectively mitigates thermal and mechanical deformation through optimized pin arrangements, enabling precise load balancing and reducing maintenance costs. Additionally, the critical role of hydrostatic lifting systems is analyzed, emphasizing how injection pocket geometry (circular, trapezoidal, rectangular) affects pressure distribution and thermal performance. Shallow pockets enhance lubrication by maintaining pressure fields, whereas deep pockets reduce effective load-bearing area, underscoring the need for design optimization to balance lift capacity and hydrodynamic efficiency.
Furthermore, the analytical methods for studying lubrication characteristics are elaborated. The Thermo-Hydrodynamic (THD) and Thermo-Elasto-Hydrodynamic (TEHD) lubrication analyses are detailed based on the Reynolds equation, which incorporates the viscosity-temperature effects and the coupled thermal-elastic deformation of pads and runner plates. While traditionally relying on simplified 2D models, advancements now emphasize the necessity of 3D TEHD analysis coupled with realistic 3D structural models for higher accuracy. The limitations of Reynolds-based methods (neglecting inertia, complex geometry simplifications, assumed boundary conditions) are highlighted. Consequently, Computational Fluid Dynamics (CFD) has emerged as a powerful tool for precise TEHD analysis. CFD enables full 3D modeling of the fluid domain, including complex features like pockets and grooves, and facilitates robust fluid-structure-thermal interaction (FSTI) simulations without a priori assumptions about heat transfer coefficients. Studies utilizing CFD, including comparisons with experimental data, validate its effectiveness in capturing the complex lubrication phenomena in large thrust bearings.
Finally, the review concludes by emphasizing four key research priorities: optimization of support structure designs, development of innovative composite materials, and deeper investigation of multi-scale lubrication mechanisms, and advancement of intelligent monitoring and maintenance of lubrication systems. Future studies should particularly focus on enhancing bearing stability under extreme operating conditions, improving material performance characteristics, refining analytical techniques to better understand transient behaviors during start-up, shutdown, and dynamic operational phases, and implementing smart operation and maintenance strategies for lubrication systems.

导出引用

杨子毅, 汤正阳, 薛炳, 李湧博, 李虎, 向艾军, 王优强. 大型水轮机组推力轴承材料与结构及其润滑性能研究进展[J]. 表面技术. 2025, 54(20): 28-43 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.003

YANG Ziyi, TANG Zhengyang, XUE Bing, LI Yongbo, LI Hu, XIANG Aijun, WANG Youqiang. Research Progress on Materials, Structures, and Lubrication Performance of Thrust Bearings in Large Hydro-turbine Units[J]. Surface Technology. 2025, 54(20): 28-43 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.003

中图分类号： TV734.1

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