ES2538426A1 - Test system for bolted connections in the wind sector (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

The testing system for bolted connections in the wind sector allows to manage and indicate each of the critical joints and give a useful support to the technicians during the tightening process, preventing errors from an initial state. It allows document management of wind turbines, wind farms, tools, personnel, procedure and work reports. As this management involves a control of the processes and procedures of tightening, it must consist of multiple tools, either physical or software, to cover the widest possible scope in relation to the execution of critical bolted connections within the wind sector. The proposed system is characterized by intelligent hydraulic control units (1), sensorized tensioning tools (2 and 3) or torque, portable control devices (4) that allow the capture of data and parameters of tightening in real time and a system of integral management of joints in wind turbines based on a web application (5). (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION OF THE INVENTION:

This invention is based on a document management system via Web combined with a system for checking bolted joints for the wind sector, which is why it is an integrated system of wind turbine connections.

This system allows to manage and indicate each one of the critical unions and give useful support to the technicians during the tightening process, preventing errors from an initial state. It allows to manage wind turbines, wind farms, tools used in the process (hydraulic switchboards, hydraulic wrenches and tensioners), personnel involved, procedure and work reports.

This system includes intelligent hydraulic control units, sensorized tools and a portable control device.

The hydraulic control units have a dual connection with the cloud through a portable control device and the sensorized tools.

The sensorized tools can be torque or tension tightening tools to which a sensor has been installed via radio frequency or cable with the intelligent control units.

The portable control device runs a web server application to collect the test or tightening data, guiding the technician to ensure the tightening work.

The configuration system is composed of a sensorized hydraulic control unit, an intelligent sensor in a torque or tensioning tool (if necessary, and one tool or another will be used depending on the method of tightening that is performed), a portable control device and the system of integral management of wind turbine unions. The system measures the parameters of the corresponding tightening process (torque or tension), determines the correct tightening, collects the measured data through the portable control device and uploads them to the integral wind turbine joint management system.

In the torque checking process, the system measures the moments when the nut is in motion. While in the tension checking process, the system measures the parameters of the tension process and determines the correct tightening. Both processes collect the measured data through the control device and download them to the integrated wind turbine joint management system.

The system software allows working in two versions: for management jobs and for field tightening jobs.

The version suitable for working in the field is designed so that the technician who performs the tightening can see the necessary data to carry out the tightening or checking process, such as the necessary hydraulic pressure. The device used has a screen optimized for field work and its software is based on Linux.

The version for management work can be executed under any platform and any web browser and allows the configuration of the system and reports. It also has a screen optimized for management work. This version allows you to configure the system and tasks, which will be sent to the version for field work, and this in turn, sends the tightening data to the version for management jobs.

This invention allows to define each type of joint, the wind turbine models, the Windmills, where they are using Google Maps plugin, all the tools and switchboards used as well as their characteristics. It also allows you to create a series of files to configure each portable system and download a new version of them, download information, upload the measurement data to the system and make reports based on the stored data.

For a better understanding of the operation of the invention, the following figures are indicated:

The figure represents a scheme of the elements that encompasses the present invention showing the tools used detailing in Figure 1 a scheme of the operation of the system. In this case, the designated tools (3) are specific for the tension tightening process. For torque tightening, these would be changed to those corresponding to this method.

Figure 2 shows the inertial sensor signal processing present in the torque wrench used in the tension tightening process.

Below is a list of the different elements represented in the figures that make up the invention:

one.

Hydraulic switchboard

2.

Sensor.

3.

Tension tightening tool (tensioner together with a torque wrench). In the case of torque tightening, a hydraulic wrench would be used.

Four.

Control device.

5.

Integral management system for wind turbine unions.

EXAMPLE OF REALIZATION OF THE INVENTION:

This checking system consists of the components indicated in figure 1. With this invention, the tightening process and the tightening verification process can be carried out. For this, the tightening is done with a torque or tensioning tool, depending on the tightening process to be performed, and, using the intelligent hydraulic control unit (1) corresponding to it.

Both the torque and tension tools can be equipped with a sensor (2) whose signal is processed as the scheme indicated in Figure 2, in which the measurement of linear (accelerometer) or angular accelerations (gyro) is obtained the angle of inclination and the angular velocity, in this way, the hydraulic control unit (1) and the control device (4) are able to collect the process data. This control device (4) is portable so that the operator who is doing the tightening can always check the necessary data, which will be displayed on the screen. Likewise, a version for office work can be used, that is, there is a version of the system in which all the data and reports of the tightening are shown, in addition to also allowing the configuration of the system. This version has a screen suitable for this job.

The workflow of this invention would be as follows:

Define each type of joint: tightening method, number of bolts, load or torque values, number of bolts to check, etc. Define wind turbine models: manufacturer, power and each type of connection defined in n previous step. Define windmills: includes the number of n previously defined.

Windmill and wind turbine place using Google Maps plugin. Every l Wind turbine and windmill on Google Maps allows full access to data. Define torque tools, hydraulic tensioners and switchboards with their main and user, plans, etc. Create MODS.tgz files to configure each n relevant and each new version for each portable system. Perform the task of tightening or checking in the field. Upload the file to the system MEASUREMENTS.csv with the measurement data. Make reports based on data stored in the system.

System configuration:

In the process of assembly and subsequent maintenance of the wind turbines, we can distinguish two relevant moments as far as the tightening is concerned: The moment of the tightening in assembly and the moment of the subsequent checks.

For each of these moments and depending on the type of tightening used (torque tightening or tension tightening) specific tools have to be used, with the precise control algorithms for each technique and the set of precise sensors. In turn, the application of data capture on the mobile device will be adapted in terms of configuration to the process to be executed by the technician. This can be summarized as follows: Processes: Tighten by Torque in Assembly - Tighten by Torque Check.

Tighten by Tension Assembly - Tighten by Tension Check

System Configuration for Torque Tightening Processes during Assembly:

With this function, the system provides a torque tightening aid during the wind turbine assembly process.

A specific switchboard will be used for the torque tightening process with microcontroller, with the torque tightening control algorithm. This switchboard controls the tightening process autonomously. The user will regulate the pressure in the control unit based on the information indicated by the mobile device, since it must first indicate what type of tightening wrench he is using. The control unit also includes a pressure transmitter, as the only sensor necessary to determine the correct tightening. For this, it uses the control algorithm developed by the company that carries out the invention. The advantage of this configuration is that any hydraulic torque wrench on the market can be used, since the system learns "the behavior of the key only by using the pressure transmitter included in the control unit.

In this case the control device is a mobile capture device, it is included in the control unit of the control unit. The user must choose in the main menu of the application the Work Mode Tighten by Torque, select the type of wind turbine in which he is going to work and select, in the options that are available, in the type of union to be tightened. All these data are available on that device, via wireless connection, and are downloaded as explained above, from the version of the integral management system of server wind turbine connections.

System Configuration for Torque Tightening Check Processes:

When it is necessary to check the state of a previously tightened joint per pair, the system configuration can be as follows:

A hydraulic switchboard identical to that mentioned in the Torque Tightening configuration or, failing that, a switchboard which has been designed and manufactured by the company that developed the present invention, and which has been specially designed to be used, will be used in checking processes, by allowing the same equipment to perform tightening processes by tension or by torque, interchangeably. In check mode, these control units have their own algorithm to determine the torque at which the bolt nut or screw to be tested moves. In this way, it becomes the system itself, which using the aforementioned sensorization (pressure transmitter) detects the movement of the nut, and through the data loaded in the mobile device, it is able to determine the tightening torque of the screw . The method to perform the check will be in the tightening direction.

System Configuration for Tensioning Tightening Processes during Assembly:

With this function, the system provides a tension tightening aid during the wind turbine assembly process.

In this case, the system configuration requires a standard tensioner (3) which is included in the puller (part responsible for traction on the bolt) an infrared measuring sensor, to determine the existence of the movement of this piece during tightening.

A sensorized torque wrench with an inertial sensor (accelerometer) will also be used.

+ Gyroscope) to determine the movement of the nut, through the gearbox. The signal processing scheme is shown in Figure 2. Both sets of sensors (present in tensioner and torque wrench) communicate wirelessly with the tension tightening control unit.

In this configuration it is necessary to use a tension switchboard (1), which also uses a pressure transmitter to control the process pressure. Using this pressure value and the hydraulic area values stored in the mobile device, it is possible to calculate the load applied to the bolt. The correct bolt tightening can be determined by means of the sensor elongation information used in the puller, together with the information received from the movement of the sensor dynamometer.

System Configuration for Tension Tightening Check Processes:

In the case of this configuration, the sensing in the tensioner is dispensed with and only the dynamized sensor and the specific control unit for the tension tightening process or the control unit designed for testing mentioned above will be used.

The check process consists of, once the tensioner is assembled correctly, actuate the control unit to raise pressure automatically while the tensioner gearbox is actuated in the direction of loosening. At the moment when the pressure reached in the pump, due to the force exerted by the tensioner, separates the nut from the flange, the technician will detect a movement with the torque wrench. The system, at that same moment stops the pump when detecting the movement of the nut and establishes as a residual load in the bolt, the result of multiplying the pressure by the hydraulic area of the tensioner.

Once the nature of the invention has been sufficiently defined, as well as a way of putting it into practice, it should be mentioned that both as a whole and in parts that compose it, it is possible to introduce changes, as long as these alterations do not substantially vary the characteristics that are indicated in the claims.

Claims (1)

shown on the mobile device (4), regulates the pressure of the automatic hydraulic control unit (1),

which is specific for this type of tightening. In the case of tension tightening, a sensor

(2)

located in the part responsible for tensioner bolt tension detects the

movement thereof during tightening, V, together with a torque wrench equipped with a

5

sensor inertial that determines the nut movement, be communicate with the switchboard

hydraulic (1) specific for this method. With the measured pressure value V the hydraulic area

of the tensioner that the operator has previously selected, the load applied to the

cap screw.

10

6. Procedure according to claim 1, characterized in that the checking system is

valid for both torque and tension tightening, where

in the first process, the

verification

be makes in sense of squeeze, V, he screw / bolt tightening torque is

determined

using the sensorization cited (transmitter from Pressure) that detect he

movement of the nut, V, through the data loaded into the mobile device. In the case of

fifteen

process from verification of the squeeze in by stressed be dispense the sensorization of the

tensioner V only uses the dynamized sensor wrench V the hydraulic control unit

automatic (1) of

way that while the control unit automatically increases pressure,

power

in direction loosen the gearbox of the tensioner until, the pump be

stops because it has detected that the nut is separated from the flange V set as residual load

twenty

in the bolt the result of multiplying the pressure by the hydraulic area of the tensioner.