CN114483476A - Intelligent monitoring system for bolt state of fan - Google Patents
Intelligent monitoring system for bolt state of fan Download PDFInfo
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- CN114483476A CN114483476A CN202011268853.5A CN202011268853A CN114483476A CN 114483476 A CN114483476 A CN 114483476A CN 202011268853 A CN202011268853 A CN 202011268853A CN 114483476 A CN114483476 A CN 114483476A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D17/00—Monitoring or testing of wind motors, e.g. diagnostics
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Abstract
The invention discloses an intelligent monitoring system for the bolt state of a fan, which belongs to the technical field of electric power and comprises a plurality of bolt state detection units, a fan signal centralized processor, a sound sensor, a cabin switch, a tower bottom switch and a server, wherein each bolt state detection unit comprises a bolt state sensor group and a laser radar, each bolt is provided with one bolt state sensor group, and each blade is provided with one bolt state detection unit, so that the technical problem of real-time monitoring of the state of a blade bolt of a wind turbine generator is solved.
Description
Technical Field
The invention belongs to the technical field of electric power, and relates to an intelligent monitoring system for the bolt state of a fan.
Background
With the increasing energy crisis in the world, the public demand for improving the ecological environment is rising. Wind power generation is used as a clean renewable energy source, except for hydroelectric generation, the cost of the renewable energy source is the closest to that of the traditional energy source, wind power has overwhelming advantages in the installed capacity of the global renewable energy source power generation, and the wind power generation has important functions of improving the environment, reducing pollutant discharge and optimizing the power structure, and the wind power generation industry is gradually developed into a primary-scale new production industry.
Wind power generation is the fastest growing energy in the world, the installed capacity growth rate per year exceeds 30%, 2 months in 2005, the kyoto protocol which aims to limit the greenhouse gas emission of developed countries to inhibit global warming takes effect, and the development of the wind power industry is positively influenced. Data published by the European wind energy Association and the global wind energy Association show that the installed capacity of the global wind energy power generation reaches 37500 megawatts in 2009, which is equivalent to the total power generation amount of 23 EPR nuclear power units.
When the Chinese wind power market is subjected to large-scale growth, the existing stock wind power installation machines and the potential newly-added installation machines bring huge development space to the wind power operation and maintenance market, and the whole machine guidance mode of the operation and maintenance market is converted into the multi-element subdivision mode, so that the operation and maintenance market presents differentiated competition cooperation situation, the prediction data shows that the Chinese market becomes the largest global wind power operation and maintenance market, and the wind power operation and maintenance market volume is increased from 80 million yuan to 350 million yuan in the last decade. The development of the wind power operation and maintenance market in China is still in the development stage, the wind field management and matching mechanism is incomplete, the situation that the operation and maintenance market which is rapidly increased is simply guaranteed by manpower is unrealistic, artificial intelligence and intelligent data processing technology are introduced into the wind power operation and maintenance field, the conventional mode of the wind power operation and maintenance is broken, the planned overhaul is changed to preventive overhaul, the fine maintenance is changed to reliable maintenance, the failure rate of the wind power equipment is continuously reduced, and the safe and reliable operation of the wind power unit is improved
The wind generating set bolt fracture accident happens sometimes, and especially the blade bolt fracture happens frequently. After the blade bolt is broken, the bolt has no detection point, so that the fan has a greater risk in operation, firstly, the broken bolt is scattered in the hub, and the devices such as a sensor, a variable pitch cabinet, the surface of the hub and the like are easily damaged, so that secondary damage to other devices is caused; secondly, after the bolts are broken, the blades are connected with the hub in an uneven stress state, and the risk of falling of the blades exists after long-term operation.
At present, no equipment and device for monitoring the bolt state in real time exist in the industry, and the bolt state is detected only by using ultrasonic flaw detection. The detection method needs to be stopped for detection, consumes a large amount of man-hour, is high in cost and is not popularized.
Disclosure of Invention
The invention aims to provide an intelligent monitoring system for the bolt state of a fan, which solves the technical problem of real-time monitoring of the bolt state of a blade of a wind turbine generator system.
In order to achieve the purpose, the invention adopts the following technical scheme:
a fan bolt state intelligent monitoring system comprises a hub and blades, wherein flanges are arranged on the hub and the blades, the flanges of the hub and the blades are fixedly connected through a plurality of bolts, the fan bolt state intelligent monitoring system comprises a plurality of bolt state detection units, a fan signal centralized processor, a sound sensor, an engine room switch, a tower bottom switch and a server, the bolt state detection units comprise bolt state sensor groups and a laser radar, each bolt is provided with one bolt state sensor group, each blade is provided with one bolt state detection unit, and all the bolt state sensor groups are communicated with the fan signal centralized processor through a data bus;
the laser radar is communicated with the fan signal centralized processor through a data line;
the sound sensor is communicated with the fan signal centralized processor through a data line;
the fan signal centralized processor is communicated with the engine room exchanger through a network cable, and the engine room exchanger is communicated with the tower bottom exchanger through a data cable;
the tower bottom exchanger communicates with the server through a data line.
Preferably, the bolt state sensor group comprises a fixed structure, a sensor box is arranged on the fixed structure, a circuit board and a vibration sensor are arranged in the sensor box, a wire harness connector is fixedly arranged on the sensor box, a proximity sensor used for detecting the position of the fixed structure is arranged beside the fixed structure, and the proximity sensor is connected with the circuit board through a wire.
Preferably, the side of the sensor box is provided with an opening, and the lead extends into the sensor box through the opening.
Preferably, a window is arranged on the sensor box, the wiring harness plug is connected with the circuit board through a data bus, and the data bus extends into the sensor box through the window.
Preferably, the fan signal centralized processor and the sound sensor are both arranged in the hub, the cabin switch is deployed in a cabin of the fan, the tower bottom switch is deployed at the tower bottom of the fan, and the server is deployed in a booster substation of the fan.
Preferably, the bolt state detection unit and the fan signal centralized processor are powered by a shaft cabinet in the hub; and the sound sensor is powered by the fan signal centralized processor.
Preferably, the fan signal centralized processor is a raspberry pi.
Preferably, be equipped with MCU and CAN bus transceiver on the circuit board, the vibration sensor with proximity sensor all is connected with the MCU electricity, CAN bus transceiver passes through data bus connects the pencil plug.
The intelligent monitoring system for the fan bolt state solves the technical problem of real-time monitoring of the state of the wind turbine blade bolt, can conveniently and quickly detect the fracture state and the bolt loosening state of the fan blade bolt, is convenient to install and maintain, can accurately and reliably detect the fracture state of the bolt, and is compact in structure and convenient to install or disassemble due to the fact that the bolt state sensor group is designed in a modularized mode.
Drawings
FIG. 1 is a system architecture diagram of the present invention;
FIG. 2 is a schematic view of the installation of the present invention;
FIG. 3 is a schematic view of the installation of the bolt state detecting unit of the present invention;
FIG. 4 is a schematic view of the internal structure of the bolt state detection unit of the present invention;
in the figure: the device comprises a bolt state detection unit 1, a laser radar 2, a blade bolt installation circumferential plane 3, a blade 4, a hub 5, a flange 6, a bolt 7, a fixing structure 8, a sensor box 9, a wire harness connector 10, a data bus 11, a proximity sensor 12, a vibration sensor 13 and a circuit board 14.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The intelligent monitoring system for the bolt state of the fan shown in fig. 1-4 comprises a hub 5 and blades 4, wherein flanges 6 are arranged on the hub 5 and the blades 4, the flange 6 of the hub 5 is fixedly connected with the flange 6 of the blades 4 through a plurality of bolts 7, and comprises a plurality of bolt state detection units 1, a fan signal centralized processor, a sound sensor, a cabin exchanger, a tower bottom exchanger and a server, wherein each bolt state detection unit 1 comprises a bolt state sensor group and a laser radar 2, each bolt 7 is provided with one bolt state sensor group, each blade 4 is provided with one bolt state detection unit 1, and all the bolt state sensor groups are communicated with the fan signal centralized processor through a data bus 11;
in this example, the laser radar 2 is arranged at the center position of the bolt installation circumferential plane 3 of the blade 4.
The laser radar 2 is communicated with the fan signal centralized processor through a data line;
the sound sensor is communicated with the fan signal centralized processor through a data line;
the fan signal centralized processor is communicated with the engine room exchanger through a network cable, and the engine room exchanger is communicated with the tower bottom exchanger through a data cable;
the tower bottom exchanger communicates with the server through a data line.
The data bus 11 is a CAN bus, a network cable, a LIN bus, a 485 bus, a ModBus bus, an EtherCAT bus or an optical fiber.
Preferably, the bolt state sensor group comprises a fixing structure 8, a sensor box 9 is arranged on the fixing structure 8, a circuit board 14 and a vibration sensor 13 are arranged in the sensor box 9, a wire harness connector 10 is fixedly arranged on the sensor box 9, a proximity sensor 12 for detecting the position of the fixing structure 8 is arranged beside the fixing structure 8, and the proximity sensor 12 is connected with the circuit board 14 through a wire.
In this embodiment, the fixing structure 8 is a fixing nut.
In the present embodiment, the proximity sensor 12 is used to detect whether or not the bolt connected to the fixed structure 8 is detached from the mounting surface.
In this embodiment, the fixing structure 8 is an M36 nut, the overall height of the bolt status sensor group is less than 45mm, and the length of the proximity sensor 12 is at least: the thickness of a standard M36 nut + washer is 5 mm.
Preferably, an opening is formed in the side surface of the sensor box 9, and the lead extends into the sensor box 9 through the opening.
Preferably, a window is arranged on the sensor box 9, the harness plug is connected with the circuit board 14 through a data bus 11, and the data bus 11 extends into the sensor box 9 through the window.
Preferably, the fan signal centralized processor and the sound sensor are both arranged in the hub 5, the cabin switch is deployed in a cabin of the fan, the tower bottom switch is deployed at a tower bottom of the fan, and the server is deployed in a booster substation of the fan.
Preferably, the bolt state detection unit 1 and the fan signal centralized processor are both powered by a shaft cabinet in the hub 5; the sound sensor is powered by the fan signal centralized processor.
Preferably, the fan signal centralized processor is a raspberry pi.
Preferably, be equipped with MCU and CAN bus transceiver on the circuit board, vibration sensor 13 with proximity sensor 12 all is connected with the MCU electricity, CAN bus transceiver passes through data bus 11 is connected the pencil plug.
In this embodiment, the circuit board is further provided with a sensor signal processing circuit for modulating signals transmitted by the bolt state sensor group, an operation control circuit for amplifying output signals of the sensor signal processing circuit, and a power supply circuit for supplying power to the circuit board, and the circuit board 14 is connected with an external communication harness through the harness connector 10 and is communicated with the fan signal centralized processor through a communication bus.
The communication bus includes but is not limited to a CAN bus, a LIN bus, a 485 bus, a ModBus bus and an EtherCAT bus.
The proximity sensor 12 includes, but is not limited to, a mechanical limit switch, a capacitive proximity sensor, an inductive proximity sensor, and an infrared sensor.
The laser radar 2 is a laser radar 2 capable of scanning by 360 degrees, or a plurality of laser radars 2 which are less than the scanning range of 360 degrees are combined to form a laser radar 2 group capable of scanning by 360 degrees. And the laser radar 2 is communicated with the fan signal centralized processor through a communication line.
The communication line includes but is not limited to an Ethernet line, a CAN bus, a USB line, a 485 bus and an RS232 line.
The fan signal centralized processor is electrically connected with all the bolt state sensors through the bus, so that communication and power supply are realized.
In this embodiment, laser radar 2 adopts dedicated installing support, fixes in bolt mounting plane centre of a circle position, and fan signal centralized processing ware adopts the mode on the spot, and demonstration and monitor terminal adopt remote mode, and data pass through switch and fiber network, upload to the bolt fracture monitored control system of distal end.
The parameters of the lidar are shown in table 1 below:
TABLE 1
The laser radar carries out 360-degree indifference detection on all bolts in the blade mounting plane, if the bolts break and fall off the mounting position, no object reflects laser at the position, and the laser radar can detect the abnormality of the position and calculate the breaking and falling position of the bolts.
The parameters of the vibration sensor are shown in table 2 below:
TABLE 2
The vibration sensor monitors bolts (such as 0 degree, 180 degrees and the like) in a high-risk area in the blade in real time in a one-to-one mode, and the vibration sensor is fastened on a screw rod of a protruding nut through threads and can also be fixed at the head of the screw in an adhesive mode. The vibration sensor collects vibration signals of the bolt in 3 directions and inputs the signals to the signal controller.
The proximity sensor is an inductive proximity sensor, and the parameters are shown in table 3 below:
TABLE 3
The proximity sensor is installed at the bolt of the high risk area, and once the bolt at the position falls off, the Hall proximity switch sends a digital signal to the processor to indicate that the bolt at the position falls off, and timely reports to operation and maintenance personnel.
The vibration sensor and the proximity sensor perform one-to-one real-time monitoring on bolts (such as 0 degree, 180 degrees and the like) in a high-risk area in the blade, and the sensors are fastened on a screw rod of the protruding nut part through threads and can also be fixed at the positions of the bolt heads through an adhesive mode.
The vibration sensor collects vibration signals of the bolt in 3 directions, and the vibration signals are processed and analyzed to obtain bolt loosening or fracture information; second, once the bolt is broken off, the proximity sensor sends a digital signal to the processor indicating that the bolt has been broken off. And a signal processor and a communication circuit module are arranged in the sensor, and the signal processor processes signals of the vibration sensor and the proximity sensor through an algorithm and sends data information to the fan signal centralized processor through a CAN (controller area network).
The parameters of the acoustic sensor are shown in table 4 below:
TABLE 4
The sound sensor is used for picking up sound signals inside the hub, sound pulse signals of the hub which is impacted after the bolts are broken are obtained after the sound signals are processed through a noise filtering technology, and whether the fan has the bolt breaking and falling conditions or not is accurately obtained.
The parameters of the fan signal central processor are shown in the following table 5:
TABLE 5
The technical parameters of the server are shown in the following table 6:
TABLE 6
In this embodiment, the fan signal centralized processor transmits data to the server side of the booster station through the cabin switch and the tower bottom switch in sequence in the fan hub in a network cable manner.
The fan signal centralized processor collects and processes laser radar signals, the bolt state sensor and the sound sensor, performs operation processing based on a multi-source information data fusion algorithm and a state diagnosis algorithm, and uploads processing results of bolt states of all blades of the fan and necessary signal characteristic information to a server through a network.
The server can receive data transmitted by all fans in the wind field through the network, the bolt states transmitted by all fans in the wind field are monitored through the bolt fracture monitoring system, and if any abnormality exists, the server can prompt and inform a manager in various modes.
In this embodiment, fix 3 vibration sensor on the nut or the bolt of high risk area bolt, fan signal centralized processing ware is through gathering the vibration signal of bolt nut on 3 degrees of freedom, and upload the vibration signal to the server, the server carries out frequency domain and time domain analysis to the vibration signal, extract key characteristic value, use the signal of normal healthy bolt nut as reference standard simultaneously, contrastive analysis and judgement are carried out to the signal of extracting, and combine the experimental test characteristic result under the different fault condition (bolt is not hard up, prestressing force is not enough, the nut is not hard up, bolt fracture etc.), in time judge the health condition of current measuring bolt, when the bolt state deviates from health condition to certain extent, will send the warning cue signal through the system.
And for bolts in a common area, a 360-degree laser radar is installed at the circle center of a bolt circumferential plane and periodically scans all bolts in the whole circumferential range, a server reads the scanning result, if a bolt is broken and departs from the installation position, the position signal abnormity can be detected through the laser radar, and the broken position of the bolt is calculated by combining the position and the angle of the starting point.
The fan signal centralized processor reads the switching value signal of the Hall proximity switch in real time, reports operation and maintenance personnel immediately after the bolt is broken and dislocated, and performs related processing according to operation procedures, so that secondary damage of equipment and major equipment accidents are avoided.
Because hall switch and vibration sensor only install on key monitoring bolt, and laser radar then has the obstacle and disturbs the problem that can't detect in certain region of a certain period of time, when certain bolt was not installed hall switch and vibration sensing device laser radar and is sheltered from simultaneously, in case take place the fracture of this department bolt and adopt noise sensing to carry out the detection of abnormal noise, judge this paddle this moment has the bolt to take place the fracture.
Aiming at the fault risk of the difference of the bolts of the wind turbine generator, the invention adopts a plurality of sensors to combine to form an intelligent hardware system, installs and connects a three-dimensional vibration sensor on the area where the bolts are easy to break, acquires three-axis vibration signals in real time, processes and analyzes data, and evaluates the severity of the looseness of the bolts at the area in real time; meanwhile, in order to reliably detect the easily broken area of the bolt of the wind turbine generator, the proximity sensor is arranged at the easily broken bolt, and a switching value signal can be acquired after the bolt is broken, so that the reliable detection of the breakage of the bolt is achieved. Installing a 360-degree laser radar sensor at the circle center of the circumferential plane of the bolt in other areas, periodically scanning the bolt in the whole circumferential range, monitoring an abnormal signal of the position of the bolt by using a laser radar once the bolt is broken and dislocated to form an installation position, and calculating the breaking condition of the bolt by combining the position and the angle of the starting point; simultaneously, a sound sensor is installed in each blade, once the laser radar, the Hoel switch and the vibration sensor do not monitor bolt breakage, noise caused by bolt breakage impact is detected by adopting noise sensing, the fan signal centralized processor acquires data of the sound sensor and uploads the data to the server, and after the server judges abnormal noise, the server judges that the bolt of the blade is broken.
The intelligent monitoring system for the fan bolt state solves the technical problem of real-time monitoring of the state of the wind turbine blade bolt, can conveniently and quickly detect the fracture condition of the fan blade bolt, is convenient to install and maintain, can accurately and reliably detect the fracture condition of the bolt, and has the advantages of compact structure and convenience in installation or disassembly because the bolt vibration sensor and the proximity sensor are in modular design.
It should be understood that portions of the present invention may be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, the various steps or methods may be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. If implemented in hardware, as in another embodiment, any one or combination of the following techniques, as are known in the art, may be used: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, an application specific integrated circuit having an appropriate combinational logic gate circuit, a Programmable Gate Array (PGA), a Field Programmable Gate Array (FPGA), or the like.
It will be understood by those skilled in the art that all or part of the steps carried by the method for implementing the above embodiments may be implemented by hardware related to instructions of a program, which may be stored in a computer readable storage medium, and when the program is executed, the program includes one or a combination of the steps of the method embodiments.
In addition, functional units in the embodiments of the present invention may be integrated into one processing module, or each unit may exist alone physically, or two or more units are integrated into one module. The integrated module can be realized in a hardware mode, and can also be realized in a software functional module mode. The integrated module, if implemented in the form of a software functional module and sold or used as a stand-alone product, may also be stored in a computer readable storage medium.
Although embodiments of the present invention have been shown and described above, it should be understood that the above embodiments are illustrative and not restrictive, and that various changes, modifications, substitutions and alterations can be made herein by those having ordinary skill in the art without departing from the scope of the present invention.
Claims (8)
1. The utility model provides a fan bolt state intelligent monitoring system, includes wheel hub (5) and paddle (4), all sets up flange (6) on wheel hub (5) and paddle (4), and several bolt (7) fixed connection, its characterized in that are passed through in flange (6) of wheel hub (5) and flange (6) of paddle (4): the system comprises a plurality of bolt state detection units (1), a fan signal centralized processor, a sound sensor, an engine room switch, a tower bottom switch and a server, wherein each bolt state detection unit (1) comprises a bolt state sensor group and a laser radar (2), each bolt (7) is provided with one bolt state sensor group, each blade (4) is provided with one bolt state detection unit (1), and all the bolt state sensor groups are communicated with the fan signal centralized processor through a data bus (11);
the laser radar (2) is communicated with the fan signal centralized processor through a data line;
the sound sensor is communicated with the fan signal centralized processor through a data line;
the fan signal centralized processor is communicated with the engine room exchanger through a data line, and the engine room exchanger is communicated with the tower bottom exchanger through the data line;
the tower bottom exchanger communicates with the server through a data line.
2. The intelligent monitoring system for the bolt state of the fan according to claim 1, characterized in that: bolt state sensor group is including fixed knot structure (8), sets up a sensor box (9) on fixed knot structure (8), is equipped with circuit board (14) and vibration sensor (13) in sensor box (9), has set firmly pencil joint (10) on sensor box (9), and the next door of fixed knot structure (8) is equipped with proximity sensor (12) that are used for detecting fixed knot structure (8) position, and proximity sensor (12) are connected with circuit board (14) through the wire.
3. The intelligent monitoring system for the bolt state of the fan according to claim 2, characterized in that: the side of the sensor box (9) is provided with an opening, and the lead extends into the sensor box (9) through the opening.
4. The intelligent monitoring system for the bolt state of the fan according to claim 3, characterized in that: the sensor box is characterized in that a windowing window is arranged on the sensor box (9), the wire harness plug is connected with the circuit board (14) through a data bus (11), and the data bus (11) stretches into the sensor box (9) through the windowing window.
5. The intelligent monitoring system for the bolt state of the fan according to claim 1, characterized in that: the fan signal centralized processor and the sound sensor are arranged in the hub (5), the engine room switch is arranged in the engine room of the fan, the tower bottom switch is arranged at the tower bottom of the fan, and the server is arranged in a booster transformer substation of the fan.
6. The intelligent monitoring system for the bolt state of the fan according to claim 1, characterized in that: the bolt state detection unit (1) and the fan signal centralized processor are powered by a shaft cabinet in the hub (5); and the sound sensor is powered by the fan signal centralized processor.
7. The intelligent monitoring system for the bolt state of the fan according to claim 2, characterized in that: the fan signal centralized processor is a raspberry pi.
8. The intelligent monitoring system for the bolt state of the fan as claimed in claim 4, wherein: be equipped with MCU and CAN bus transceiver on the circuit board, vibration sensor (13) with proximity sensor (12) all are connected with the MCU electricity, CAN bus transceiver is connected with the MCU electricity, CAN bus transceiver passes through data bus (11) are connected the pencil plug.
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| US20220145848A1 (en) * | 2019-03-14 | 2022-05-12 | Wobben Properties Gmbh | Flange connection, wind turbine having same, and method for monitoring same |
| CN115307537A (en) * | 2022-09-15 | 2022-11-08 | 雅砻江流域水电开发有限公司 | Hydraulic generator foundation bolt intelligent monitoring system |
| CN116517785A (en) * | 2023-04-06 | 2023-08-01 | 中广核全椒风力发电有限公司 | Monitoring system and monitoring method for monitoring breakage of blade bolt of wind turbine generator |
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