CN103472741A - Control system for fatigue certification experimental test on blades of wind turbine - Google Patents
Control system for fatigue certification experimental test on blades of wind turbine Download PDFInfo
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Abstract
The invention discloses a control system for a fatigue certification experimental test on the blades of a wind turbine. The control system comprises a test bed, a load vibration device, a strain gauge, a bridge-type strain processor, a high-speed synchronous data acquisition card, a computer, a storage and a display, wherein the bridge-type strain processor comprises a shunt calibration module capable of recalibrating the sensitivity of the strain gauge, a bridge circuit temperature compensation module capable of compensating an environmental temperature change, and a linear expansion coefficient error between the strain gauge and a tested blade material, and a strain value return-to-zero module capable of returning the initial strain value of the tested blade to zero; an automatic control monitoring module and a test data processing module are installed in the computer, the automatic control monitoring module is used for comparing real-time test strain signal data with a designed value so as to judge whether the test strain value is in the range of the designed value, and deciding whether the output for an invariable-frequency control signal, a variable-frequency control signal or a shut-down control signal of a frequency converter is kept or not according to the judged result, and the test data processing module is used for converting strain voltage signal data to an actual strain measured value.
Description
Technical field
The present invention relates to test control system, specifically the tired certification test test control system of a kind of blade of wind-driven generator.
Background technology
Wind wheel blade is one of critical component of aerogenerator, and the Design and manufacture quality of blade directly has influence on operational efficiency, serviceable life and the acting performance of aerogenerator.Introduction and digestion along with the blade of wind-driven generator technology, China also starts autonomous Design and produces the blade of MW class wind turbine, by its commercialization, but, the commercialization of blade of wind-driven generator must obtain corresponding international organization and authenticate, the authentication of the fatigue of blade of wind-driven generator is IEC(International Electrotechnical Commission) one of requisite authentication item in standard, the purpose of its authentication is: find technique irrationality and the manufacturing defect in blade design and manufacture process 1., consistance and the reliability of checking blade design and manufacture, and for improving from now on design, manufacture and subsequent treatment provide reliable basis, 2. guarantee that blade meets or exceeds 20 years serviceable life, 3. in tired certification test, within the strain value of the tired certification test Leaf of General Requirements sensitive spot is controlled at design load ± 5% scope, only in tired certification test process, after guaranteeing that test repeated strain value is within design calculated value institute permissible range, can assert that Design and manufacture has consistance, and can assert reliability, the feasibility of Design and manufacture.
The tired certification test of blade of wind-driven generator mainly comprises following action: independently complete respectively the tired certification test that blade is waved (flapwise) and shimmy (edgewise) direction 1.; 2. at blade, wave and shimmy direction difference installed load exciting device and static counterweight, measure the natural frequency of single blade, according to the repeated strain value recorded and the comparing result of design load, adjust the output frequency of frequency converter, raise or reduce the exciting force in torture test.
Because the test macro that has the tired certification test of blade of wind-driven generator now is the open test system that does not have automatic control monitoring function, mainly there is following problem in it: in tired certification test process, once the repeated strain of blade sensitive spot is not within the zone of reasonableness of design load, be merely able to by the output frequency of artificial adjustment frequency converter, increase or reduce the exciting force of torture test, but, the torture test of an operating mode of blade often needs to continue to carry out the even trimestral time of two weeks, in the process of tired certification test, blade easily is subject to the impact of the factors such as environment temperature and the heating of blade self material, certain variation (for example will occur in its rigidity, when environment temperature is low, the rigidity of blade will increase, otherwise anti-), thereby cause the strain value of blade sensitive spot to change, even surpass or lower than the strain value of blade fatigue design, once the repeated strain tested, be worth improper, need by the output frequency of artificial adjustment frequency converter, control the repeated strain of blade sensitive spot within rational scope, this not only can increase artificial work load greatly, and there is very large subjectivity in artificial the adjustment, accurately and poor reliability, easily make blade in process of the test, the repeated strain value of its sensitive spot surpasses or lower than the fatigue design value, thereby can not meet the requirement of the tired certification test of blade, while particularly when the blade stiffness variation, causing Natural Frequency of Blade to change thereupon, to likely cause tired excited frequency to overlap with Natural Frequency of Blade and produce resonance, now, once artificial treatment not in time, will greatly increase the danger of tired certification test, even can cause the security incident of blade damage.
Summary of the invention
The object of the invention is to: for the deficiency of above-mentioned existing test macro, provide a kind of blade of wind-driven generator simple to operate, that the automatic intelligent degree is high, test data is accurate, safety and reliability is high, practical tired certification test test control system.
The technical solution used in the present invention is, the tired certification test test control system of a kind of blade of wind-driven generator, and described test control system comprises:
-testing table, described testing table is for installing tested blade;
-load exciting device, described load exciting device is for applying dynamic Fatigue Testing Loads to tested blade, and the excited frequency of load exciting device is by Frequency Converter Control;
-foil gauge, described foil gauge is a plurality of, and each foil gauge is self-temperature-compensated strain ga(u)ge, and a plurality of foil gauges are located at respectively on each sensitive spot of tested blade, for detection of the repeated strain value of tested blade each sensitive spot under Fatigue Testing Loads;
-bridge-type strained handling device, the repeated strain signal data that described bridge-type strained handling device arrives for the treatment of all strain measurements; Bridge-type strained handling device comprises shunting calibration module ,Qiao road temperature compensation module and the strain value module that makes zero, and described shunting calibration module for recalibrating the sensitivity of foil gauge, to eliminate the impact of stube cable on foil gauge sensitivity before test; Described bridge road temperature compensation module is for the error of the linear expansion coefficient between compensate for ambient temperature variation and foil gauge and tested blade material, to realize round-the-clock tested blade being carried out to torture test; The module that makes zero described strain value makes zero for the strain initial value by tested blade;
-high-speed synchronous data acquiring card, described high-speed synchronous data acquiring card becomes digital signal for foil gauge analog signal conversion that bridge-type strained handling device is obtained, and high-speed synchronous collection and keep these signal datas, and these signal datas are flowed to computing machine;
-computing machine, be equipped with automatic control monitoring modular and testing data processing module in described computing machine, real-time testing strain signal data and design load that described automatic control monitoring modular transports the high-speed synchronous data acquiring card are contrasted, within judging with this whether the test strain value is in the scope of design load, if, the exciting force that shows the current output of load exciting device meets the torture test requirement, keep current excited frequency and the eccentric weight quality of load exciting device, if not, the exciting force that shows the current output of load exciting device need to be regulated change, automatically control monitoring modular and send the frequency change control signal that raises or reduce according to comparing result to frequency converter, the frequency of exporting by frequency converter changes the excited frequency of the tested blade of load exciting device exciting, if after the excited frequency that changes the load exciting device, the real-time testing strain signal data that the high-speed synchronous data acquiring card collects have still exceeded the design load scope or have reached setting dangerous values scope, automatically control monitoring modular and export stopping signal to frequency converter, the action of Ending Load exciting device, described testing data processing module, for the treatment of the voltage signal data of foil gauge output, converts the compliance voltage signal data to actual strain measurement value,
-storer, described storer is for storing the measuring-signal data of foil gauge output;
-display, described display is used for showing the measured value of foil gauge output signal after treatment and excited frequency and the fatigue life cycle of current tested blade.
Further, be set with frequency conversion higher limit and frequency conversion lower limit in described frequency converter.
Further, described automatic control monitoring modular is natural frequency that tested blade is tested to the frequency conversion value of frequency converter output 80～95%.
Further, described load exciting device mainly consists of reductor and eccentric weight exciting agency, the load exciting device is fixed on tested blade by fixture, the reductor of load exciting device drives the action of eccentric weight exciting agency, and the exciting force of eccentric weight exciting agency passes to tested blade by fixture.
Further, the temperature self-compensation ambient temperature range of described foil gauge is-20～40 ℃.
Further, described foil gauge is by the room temperature fast-curing glue on the sensitive spot of tested blade, and the exposed surface of foil gauge scribbles the protective finish of waterproof and dustproof.
The invention has the beneficial effects as follows: above-mentioned testing fatigue control system can be applied to the tired certification test test of blade of wind-driven generator that all natural frequencys are greater than 0.9Hz, in the tired certification test process of blade, can meet the data acquisition of test strain signal and the storage work of 16 test channel, simultaneously, it can also meet the static(al) certification test test of blade of wind-driven generator; Above-mentioned test control system mainly can be realized following functions:
1). Natural Frequency of Blade and damping test;
2). automatically realize shunting calibration (shunt calibration), guarantee to test the strain signal data accurately, reliable, the precision that makes to test the strain signal data is not subject to the impact of conductor length;
3). automatically realize ambient temperature compensation, the error that elimination brings because of the factors such as linear expansion coefficient between variation of ambient temperature and foil gauge and tested blade material, further ensure accuracy and the reliability of test strain signal data, to realize round-the-clock tested blade being carried out to tired certification test;
4). automatically realize the work of making zero (Offset Null Compensation) of strain initial testing data, reduced the workload of artificial treatment test data, its principle be utilize digital potentiometer by the output valve of bridge voltage regular be zero;
5). realize the synchronous of multi-point sampler strain signal data and keep function (Simultaneous Sample and Hold), strict guarantee synchronous, the real-time of multi-point sampler strain signal data;
6). automatically realize that test strain signal data and design load are contrasted, and within whether being in the scope of design load according to comparing result judgement test strain signal data, export corresponding maintenance, frequency conversion, shutdown control signal according to judged result, the control of realization to the frequency converter output frequency, thereby the control of the realization of automatic intelligent to whole system, alleviate the hand labor load, the security of safeguards system, tested blade and experimenter's person;
7). according to the shutdown control signal to frequency converter output, synchronously send early warning signal, remind the experimenter to note and check failure and other reasons;
8). the test data to the tired certification test of blade realizes simultaneous display and storage; And the storage of test data can be divided into two parts, wherein part employing FIFO(first in first out) mode is stored (for example strain waveform data in nearest two hours), another part adopts regularly preserving type to store positive peak and the negative peak strain value of each sensitive spot of tired certification test test overall process, data file can all adopt binary format, thereby saves the storage space of computer memory;
9). according to the natural frequency that tested blade is recorded, frequency conversion higher limit and frequency conversion lower limit are set on frequency converter, thereby set the operating frequency range of frequency converter, to frequency converter output frequency change control signal the time, the frequency change control signal that simultaneously can in automatically controlling monitoring modular, set output by the test natural frequency 80～95%, again realize the restriction to the frequency converter frequency working range, and then, more than guaranteeing that tired certification test can not be operated in tested Natural Frequency of Blade point, guarantee the security of system, tested blade and experimenter's person so that dual.
The accompanying drawing explanation
Below in conjunction with accompanying drawing, the present invention is further illustrated.
Fig. 1 is formation of the present invention and uses the status architecture schematic diagram.
Fig. 2 is topology diagram of the present invention.
Fig. 3 is software program structural drawing of the present invention.
Fig. 4 is test flow chart of the present invention.
Fig. 5 is control principle drawing of the present invention.
Embodiment
Formation of the present invention and use status architecture are referring to Fig. 1, bridge-type strained handling device of the present invention, each function of automatically controlling monitoring modular and testing data processing module realize by the software based on the Labview establishment fully, and topological structure of the present invention, software program structure are referring to Fig. 2 and Fig. 3.The present invention includes testing table 1, load exciting device, foil gauge 5, bridge-type strained handling device 6, high-speed synchronous data acquiring card 7, computing machine 12, storer 10 and display 11.
Wherein, testing table 1 is for installing tested blade 2, and tested blade 2 laterally is assemblied on testing table 1.
The load exciting device mainly consists of reductor 4 and eccentric weight exciting agency, the load exciting device is fixed on tested blade 2 by fixture, in case tested blade 2 is caused to damage, the reductor 4 of load exciting device drives the action of eccentric weight exciting agency, the exciting force of eccentric weight exciting agency passes to tested blade 2 by fixture, make tested blade 2 produce upper and lower Fatigue Vibration, the load exciting device is for applying dynamic Fatigue Testing Loads to tested blade 2.Reductor 4 gyro frequencys are controlled by the frequency converter 3 be connected with computing machine 12, according to the natural frequency that tested blade 2 is recorded, are set with frequency conversion higher limit and frequency conversion lower limit in frequency converter 3, thereby set the operating frequency range of frequency converter 3.
Foil gauge 5 is a plurality of; each foil gauge 5 is self-temperature-compensated strain ga(u)ge; their temperature self-compensation ambient temperature range is-20～40 ℃; these foil gauges 5 are by the room temperature fast-curing glue on the sensitive spot of tested blade 2, and each exposed surface of foil gauge 5 scribbles the protective finish of waterproof and dustproof.Tested blade 2 produces upper and lower Fatigue Vibration under the effect of load exciting device, make each sensitive spot of tested blade 2 that corresponding repeated strain occur, these foil gauges 5 are for detection of the repeated strain value of tested blade 2 each sensitive spot distortion under Fatigue Testing Loads.
The repeated strain signal data that bridge-type strained handling device 6 arrives for the treatment of all strain measurements, this bridge-type strained handling device 6 comprises shunting calibration module ,Qiao road temperature compensation module and the strain value module that makes zero.The shunting calibration module, for before experimental test, is recalibrated the sensitivity of foil gauge, to eliminate the impact of stube cable on foil gauge 5 sensitivity.Bridge road temperature compensation module is for the error of the linear expansion coefficient between compensate for ambient temperature variation and foil gauge 5 and tested blade 2 materials, thereby further reduce the affected by environment and test error that brings of foil gauge 5 in the experimental test process, to realize round-the-clock tested blade 2 being carried out to tired certification test.The module that makes zero strain value makes zero for the strain initial value by tested blade 2.
High-speed synchronous data acquiring card 7 becomes digital signal for the foil gauge analog signal conversion that bridge-type strained handling device 6 is obtained, and high-speed synchronous collection and keep these signal datas, and these signal datas are flowed to computing machine 12.
Automatic control monitoring modular 8 and testing data processing module 9 are housed in computing machine 12.Automatically control monitoring modular 8 transports high-speed synchronous data acquiring card 7 real-time testing strain signal data and design load are contrasted, within judging with this whether the test strain value is in the scope of design load, if, show that the excited frequency of the current output of load exciting device is suitable, automatically control monitoring modular 8 lockings, keep the current excited frequency of load exciting device, if not, the excited frequency that shows the current output of load exciting device need to be regulated change, automatically control monitoring modular 8 and send the frequency change control signal that raises or reduce according to comparing result to frequency converter 3, change the exciting force size of the tested blade of load exciting device exciting by the frequency of frequency converter 3 outputs, in order further to guarantee fatigue test system, the safety of tested blade and experimenter's person, automatically controlling in monitoring modular 8 the variable frequency control scope to frequency converter 3 outputs that arranged, 80～95% of test natural frequency that its frequency conversion scope is tested blade 2, again to realize the restriction to frequency converter 3 variable frequency work scopes, and then more than guaranteeing that tired certification test can not be operated in the natural frequency point of tested blade 2, if after the excited frequency that changes the load exciting device, the real-time testing strain signal data that high-speed synchronous data acquiring card 7 collects have still exceeded the design load scope or have reached setting dangerous values scope, automatically control monitoring modular 8 to frequency converter 3 output stopping signals, the work of Ending Load exciting device, meanwhile, automatically control monitoring modular 8 output early warning signal automatically, this early warning signal will exceed the scope of design value and set dangerous values and carry out heterochromatic marking, the early warning result demonstrates by display 11, to remind the experimenter to note and to check failure and other reasons.The compliance voltage signal data that testing data processing module 9 collects for the treatment of high-speed synchronous data acquiring card 7, convert the compliance voltage signal data to actual strain measurement value.
Storer 10 can embeddeding computer 12 in, also can be external outside computing machine 12.Storer 10 is for the measuring-signal data of the foil gauge output of storing machine 12 as calculated and having processed, in order to store comprehensively, reliably data, can consider storer 10 is divided into to two parts, wherein part employing FIFO(first in first out) mode is stored (for example strain waveform data in nearest two hours), another part adopts regularly preserving type to store positive peak and the negative peak strain value of each sensitive spot of tired certification test test overall process, data file can all adopt binary format, thereby saves the storage space of computer memory.
The measured value of display 11 foil gauge output signal after computing machine 12 is processed for demonstration and excited frequency and the fatigue life cycle of current tested blade 2.
In order to check the residual intensity of tested blade after torture test, by set up static(al) test module, long-range apart from detection module, force cell etc. to the present invention, can realize the static(al) test of tested blade residual intensity.
Testing process of the present invention is referring to Fig. 4, and control principle of the present invention is referring to Fig. 5.In the process of the tired certification test of blade, automatically controlling monitoring and adjusting tested blade sensitive spot repeated strain value is one of gordian technique of the present invention, it need to possess two functions, one is: when main sensitive spot strain value surpass the design strain 15% after, automatically stop frequency converter frequency output, the Fatigue Testing Loads that then stops tested blade loads; Its two: when main sensitive spot strain value surpass the design strain 10% the time; automatically controlling monitoring modular is just adjusted excited frequency with predefined frequency converter frequency conversion scope; within Fatigue Testing Loads is adjusted to suitable scope; if still Fatigue Testing Loads can not be adjusted to OK range in given frequency converter setting range within; export stopping signal and stop torture test, so that testing crew is searched reason and solved corresponding fault.For this reason, this is automatically controlled monitoring modular and need to complete following functions:
1). can automatically control the output frequency of frequency converter;
2). when theoretical strain value surpasses 5～10% with the error of testing strain value, automatically adjust the output frequency of frequency converter, its adjustment step-length and frequency adjustment range are optional, to making to test the requirement that the repeated strain value meets torture test, if can not make Theoretical Design repeated strain value when the error of test strain value is in correct scope by the output frequency of adjusting frequency converter, export stopping signal and stop torture test;
3). when the error of any one output test repeated strain value and Theoretical Design repeated strain value reaches 15%, export stopping signal and make torture test stop;
4). the output frequency that frequency converter is set is 0～natural frequency, prevents that the frequency converter hypervelocity from causing unnecessary danger;
5). in automatically controlling monitoring modular, again limit the frequency output area of frequency converter, the scope of its setting is left and right, 0～tested Natural Frequency of Blade ' (90～95%), mainly for preventing the natural frequency of frequency converter output frequency near blade, cause blade produce resonance or produce larger heat and damaged blade in torture test.
Below introduce the course of work of the present invention: at first before test according to the test specification of concrete tested blade, determine the needed load loading position of tested blade and the configuration corresponding sensitive spot the strain testing passage, blades installation, on flapwise or edgewise direction, is then installed to corresponding tired exciting device (being the load exciting device) and static counterweight, after installation, test and determine the natural frequency of tested blade, according to the natural frequency of tested blade, set at frequency converter and automatic control on monitoring modular the reference frequency output that limits frequency converter respectively, then start frequency converter by automatically controlling monitoring modular, and the output frequency of the frequency converter that progressively raises, the repeated strain of each sensitive spot under Real-time Collection and the corresponding exciting force of demonstration, after once the strain of each sensitive spot reaches Theoretical Design repeated strain design load, lock the output frequency of frequency converter, simultaneously, starting the Vibrating Load of automatically controlling in monitoring modular adjusts automatically, report to the police and stopping function, now, tired certification test will carry out according to normal program, once unexpected shutdown the in the torture test process, the experimenter will be according to the repeated strain of the stored waveform of two hours and regularly storage just, negative peak, judge the reason of termination test, in the reason that finds termination test and after doing respective handling, can enough restart tired certification test.
Claims (6)
1. the tired certification test test control system of blade of wind-driven generator, is characterized in that, described test control system comprises:
-testing table, described testing table is for installing tested blade;
-load exciting device, described load exciting device is for applying dynamic Fatigue Testing Loads to tested blade, and the excited frequency of load exciting device is by Frequency Converter Control;
-foil gauge, described foil gauge is a plurality of, and each foil gauge is self-temperature-compensated strain ga(u)ge, and a plurality of foil gauges are located at respectively on each sensitive spot of tested blade, for detection of the repeated strain value of tested blade each sensitive spot under Fatigue Testing Loads;
-bridge-type strained handling device, the repeated strain signal data that described bridge-type strained handling device arrives for the treatment of all strain measurements; Bridge-type strained handling device comprises shunting calibration module ,Qiao road temperature compensation module and the strain value module that makes zero, and described shunting calibration module for recalibrating the sensitivity of foil gauge, to eliminate the impact of stube cable on foil gauge sensitivity before test; Described bridge road temperature compensation module is for the error of the linear expansion coefficient between compensate for ambient temperature variation and foil gauge and tested blade material, to realize round-the-clock tested blade being carried out to torture test; The module that makes zero described strain value makes zero for the strain initial value by tested blade;
-high-speed synchronous data acquiring card, described high-speed synchronous data acquiring card becomes digital signal for foil gauge analog signal conversion that bridge-type strained handling device is obtained, and high-speed synchronous collection and keep these signal datas, and these signal datas are flowed to computing machine;
-computing machine, be equipped with automatic control monitoring modular and testing data processing module in described computing machine, real-time testing strain signal data and design load that described automatic control monitoring modular transports the high-speed synchronous data acquiring card are contrasted, within judging with this whether the test strain value is in the scope of design load, if, the exciting force that shows the current output of load exciting device meets the torture test requirement, keep current excited frequency and the eccentric weight quality of load exciting device, if not, the exciting force that shows the current output of load exciting device need to be regulated change, automatically control monitoring modular and send the frequency change control signal that raises or reduce according to comparing result to frequency converter, the frequency of exporting by frequency converter changes the excited frequency of the tested blade of load exciting device exciting, if after the excited frequency that changes the load exciting device, the real-time testing strain signal data that the high-speed synchronous data acquiring card collects have still exceeded the design load scope or have reached setting dangerous values scope, automatically control monitoring modular and export stopping signal to frequency converter, the action of Ending Load exciting device, described testing data processing module, for the treatment of the voltage signal data of foil gauge output, converts the compliance voltage signal data to actual strain measurement value,
-storer, described storer is for storing the measuring-signal data of foil gauge output;
-display, described display is used for showing the measured value of foil gauge output signal after treatment and excited frequency and the fatigue life cycle of current tested blade.
2. the tired certification test test control system of blade of wind-driven generator according to claim 1, is characterized in that, is set with frequency conversion higher limit and frequency conversion lower limit in described frequency converter.
3. the tired certification test test control system of blade of wind-driven generator according to claim 1, is characterized in that, described automatic control monitoring modular is natural frequency that tested blade is tested to the frequency conversion value of frequency converter output 80～95%.
4. the tired certification test test control system of blade of wind-driven generator according to claim 1, it is characterized in that, described load exciting device mainly consists of reductor and eccentric weight exciting agency, the load exciting device is fixed on tested blade by fixture, the reductor of load exciting device drives the action of eccentric weight exciting agency, and the exciting force of eccentric weight exciting agency passes to tested blade by fixture.
5. the tired certification test test control system of blade of wind-driven generator according to claim 1, is characterized in that, the temperature self-compensation ambient temperature range of described foil gauge is-20～40 ℃.
6. according to the tired certification test test control system of the described blade of wind-driven generator of claim 1 or 5; it is characterized in that; described foil gauge is by the room temperature fast-curing glue on the sensitive spot of tested blade, and the exposed surface of foil gauge scribbles the protective finish of waterproof and dustproof.
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