CN104931185A - Method and equipment for evaluating technological property of bolt installation - Google Patents
Method and equipment for evaluating technological property of bolt installation Download PDFInfo
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- CN104931185A CN104931185A CN201510295782.0A CN201510295782A CN104931185A CN 104931185 A CN104931185 A CN 104931185A CN 201510295782 A CN201510295782 A CN 201510295782A CN 104931185 A CN104931185 A CN 104931185A
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- stress amplitude
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Abstract
The invention relates to a method and equipment for evaluating the technological property of bolt installation, and the method comprises the steps: determining the fastening sequence of bolts; testing the total pulling force of bolts in an operation process under the condition of different loads; obtaining a real-time stress amplitude value; making a conclusion that an end face of a connected part is cracked when the real-time stress amplitude value is greater than a standard stress amplitude value; and determining the fastening sequence of new bolts till the fastening sequence of the current bolt is judged to be the optimal bolt fastening sequence. The equipment comprises a signal input end module, a signal collection and processing module, and a man-machine interaction module, wherein the signal input end module comprises a strain signal input end, a standard analog input end, and a power circuit. The signal collection and processing module comprises a processing chip. The man-machine interaction module comprises a processor, a communication interface, an operation module, and a display module. The method and equipment can test the bolts, propose a new installation technology, and facilitate the maintenance of the bolts.
Description
Technical field
The present invention relates to that bolt is safeguarded, detection field, particularly relate to and be a kind ofly applicable to Wind turbines pitch variable bearings, the driftage bolt mounting process performance estimating method of bearing and equipment.
Background technology
According to the quality system statistics of certain blower fan manufacturer, Wind turbines bolt failure rate became ascendant trend in recent years.Bolt fracture can cause leaf abscission, Wind turbines falls the problems such as tower; in addition; bolt fracture also can cause the damage of Wind turbines inside and neighbouring parts; thus cause Wind turbines to be shut down for a long time; even can therefore the relevant large parts of dismounting must be gone to change, these problems can bring many adverse effects to wind-power market.At present, connect the bolt of pitch variable bearings and wheel hub, crack conditions is particularly outstanding, accounts for about 80% of break bolt sum., there is the just accumulative up to nearly 300 of pitch variable bearings bolt fracture situation in the only 1.5MW Wind turbines of applicant's maintenance.Part field causes being discontented with of owner because bolt frequently ruptures, had a strong impact on the returned money after sale of Wind turbines.
The bolt that the bolt that the driftage bearing of Wind turbines is connected with base, pitch variable bearings are connected with wheel hub and the bolt that pitch variable bearings is connected with blade all easily rupture, can only be changed as requested after discovery bolt fracture by field maintenance person at present, such processing mode also exists certain drawback and limitation:
1, after there is bolt fracture fault at present, just simply change, general meeting changes break bolt and adjacent 5 bolts thereof according to workshop manual, when break bolt quantity is more, can change the bolt of whole flange connection surface, not only spare parts consumption is large, and workload is also large, sometimes in order to take out fracture of wire, speciality tool and cost longer time must be bought;
2, the project that has is on-the-spot, also there is the problem that bolt changes more disconnected and more disconnected, after having changed bolt, new bolt every 1 year even deficiency namely again rupture half a year;
After raising bolt strength grade and construction moment, still there is bolt fracture fault, even damaged bolt hole in the scene 3, had.
In sum, at present for bolt fracture problem, everybody is only directed to the material quality, bolt strength grade etc. of bolt individuality because usually analyzing bolt fracture reason, notice is not put into whole flange face whole removing and considers the stressed of bolt, have ignored bolt connection is the entirety comprising bolt, bolt connector.
As can be seen here, above-mentioned existing Wind turbines bolt is changed with the method that is maintained in in use, and obvious exist inconvenience and defect, and be urgently further improved.How to found one and can carry out load test to bolt, and bolt mounting process performance estimating method and the equipment of bolt fracture reason, design improvement project can be judged according to test result, one of current important research and development problem of real genus.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of bolt mounting process performance estimating method and equipment, make it can carry out load test to bolt, and judge fracture cause according to the tested results, design new mounting process, then new mounting process is tested again, continuous correction mounting process, thus overcome the deficiencies in the prior art.
For solving the problems of the technologies described above, a kind of bolt mounting process of the present invention performance estimating method, is characterized in that comprising the following steps: A. determines the tightening sequence of each bolt on flange face; B. while fastening bolt, packing ring pressure transducer is installed between flange face and coupling bolt, after bolted completes, is obtained the distribution of the bolt pretightening on circumference of flange end face by gasket pressure sensor measurement; C. certain operating load is applied to bolt, the real-time total pulling force F of bolt in test unit running process under different operating load
0, draw F
0waving interval F
01-F
02, and calculate the real-time stress amplitude σ of bolt
a, described in
wherein d
cfor the diameter of this bolt; D. by the real-time stress amplitude σ of all bolts
acompare with its standard stress amplitude, when described real-time stress amplitude is greater than standard stress amplitude, show that the conclusion in gap appears in connected piece end face, and return steps A and determine new bolted order, otherwise determine that current bolted order is for optimum bolted order.
As a modification of the present invention, further comprising the steps of between described step B, C: the pretightning force of this bolt detected and its standard pretightning force are compared, when described pretightning force is not equal to standard pretightning force, judge whether the quality whether bolt does not smear solid lubrication cream, cup grease and bolt on request has problem, whether the pre-fastening moment value T of setting meets standard, and return the order that step B determines according to steps A again and correct technique and fastening each bolt according to described judgement.
Described gasket pressure sensor is resistance-type gasket pressure sensor, piezoelectric type gasket pressure sensor or condenser type gasket pressure sensor, and described gasket pressure sensor is provided with 8 pasters.
In addition, present invention also offers a kind of bolt mounting process Performance Evaluation equipment of using said method, comprise signal input part module, Signal sampling and processing module and human-computer interaction module, wherein: described signal input part module comprises independent the strain signal input end, 4 road sign quasi-mode analog quantity input ends and the power circuit that provides driving source to export for strain signal that arrange; Described Signal sampling and processing module comprises process chip, and described power circuit is that described process chip is powered, and described 4 road sign quasi-mode analog quantity signal input parts and strain signal input end are connected with process chip by analog to digital conversion circuit; Described human-computer interaction module comprises processor, communication interface, operational module and display module, and the output terminal of described process chip is connected respectively with described processor, communication interface, and described operational module is all connected with processor with display module.
As further improvement, the signal of described strain signal input end is after programmable amplifier conditioning, and a road is input to described process chip through analog to digital conversion circuit, and another road is direct and process chip is mutual.
Described process chip adopts FPGA integrated circuit, and described processor adopts X86-based, and described communication interface comprises two network interfaces and three USB interface, and described operational module comprises action button and tutorial light, and described display module adopts LCD display.
Described strain signal is 12.
After adopting such design, the present invention at least has the following advantages:
1, the present invention effectively can detect the pretightning force of bolt, the operating load change of bolt in running of wind generating set process, the physical quantitys such as the total pulling force variation tendency of bolt, thus analysis causes the tired source of bolt fatigue break and stress amplitude to change excessive reason, and judge the feasibility of bolted technique according to this, calculate bolted torque coefficient, find out the basic reason of bolt failure fast, test result can be used as follow-uply carries out technique, the foundation that design etc. improve, thus be beneficial to the FATIGUE FRACTURE PROBLEMS fundamentally solving bolt, reach the object avoided bolt fracture and extend bolt life,
2, the present invention effectively can reduce the number of stoppages and stop time that bolt failure causes, reduce the risk of such as falling tower because bolt fracture causes, becoming the secondary harm such as the damage of oar cabinet, slip ring damage, promote the reliability that Wind turbines uses bolt, the market competitiveness of improving product;
3, the present invention is as test macro newly developed, not yet finds similar substitution up to now, can carry out relevant bolt and detect business, and to expand blower fan after sale service business, the O&M improving Wind turbines is worth.
Accompanying drawing explanation
Above-mentioned is only the general introduction of technical solution of the present invention, and in order to better understand technological means of the present invention, below in conjunction with accompanying drawing and embodiment, the present invention is described in further detail.
Fig. 1 is the schematic flow sheet of a kind of bolt mounting process of the present invention performance estimating method.
Fig. 2 is the composition schematic diagram of bolt mounting process Performance Evaluation equipment of the present invention.
Fig. 3 is the paster distribution schematic diagram of the sensor in the present invention.
Fig. 4 is the circuit distribution schematic diagram of the sensor in the present invention.
Embodiment
Cause the reason of bolt fracture a lot, the bolt fracture characteristic of different type of machines and diverse location is different, must understand its basic reason ruptured, then change the bolt of fracture with correct mounting process, could realize the Rational Maintenance to bolt.
Please specifically consult shown in Fig. 1, a kind of bolt mounting process performance estimating method, comprises the following steps:
A. the tightening sequence of each bolt on flange face is determined;
B. while fastening bolt, packing ring pressure transducer is installed between flange face and coupling bolt, after bolted completes, is obtained the distribution of the bolt pretightening on circumference of flange end face by gasket pressure sensor measurement;
C. certain operating load is applied to bolt, the waving interval F of the real-time total pulling force of bolt in test unit running process under different operating load
01-F
02, and calculate the real-time stress amplitude σ of bolt
a, described in
wherein d
cfor the diameter of this bolt;
D. by the real-time stress amplitude σ of all bolts
acompare with its standard stress amplitude, when described real-time stress amplitude is greater than standard stress amplitude, show that the conclusion in gap appears in connected piece end face, and return steps A and determine new bolted order, otherwise determine that current bolted order is for optimum bolted order.
Further specifically, further comprising the steps of between described step B, C: the pretightning force of this bolt detected and its standard pretightning force are compared, when described pretightning force is not equal to standard pretightning force, judge whether the quality whether bolt does not smear solid lubrication cream, cup grease and bolt on request has problem, whether the pre-fastening moment value T of setting meets standard, and return the order that step B determines according to steps A again and correct technique and fastening each bolt according to described judgement.
The pretightning force of bolt and total pulling force are measured in real time by the gasket pressure sensor be arranged between flange face and coupling bolt.Gasket pressure sensor can be resistance-type gasket pressure sensor, piezoelectric type gasket pressure sensor or condenser type gasket pressure sensor, and gasket pressure sensor is provided with 8 pasters, improves the sensitivity level of sensor.In addition, can increase according to the quantity of local bolt fracture or reduce number of sensors.
In tools for bolts ' pretension process, tools for bolts ' pretension moment value: T=T
1+ T
2=k
t× F' × d
c(1).In formula: T is tools for bolts ' pretension moment value, and unit is Nm; T
1be the moment of friction between screw thread pair, unit is Nm; T
2be the frictional resistance moment between nut seat, unit is Nm; k
tit is moment coefficient; F' is bolt pretightening, and unit is kN; d
cbe the diameter of bolt, unit is m.
When tools for bolts ' pretension moment value is determined, bolt pretightening only with moment coefficient k
trelevant, the k of existing bolt tightening technique
t, be all determine under the prerequisite of smearing solid lubrication cream, if the new bolt changed does not smear solid lubrication cream on request, pretightning force is less than or greater than standard pretightning force in real time.Same, at Bolt Tightening Torque Coefficient k
twhen determining, bolt pretightening is only relevant to tools for bolts ' pretension moment value, and the real-time pretightning force of bolt can be caused when tools for bolts ' pretension moment value is large time to become large.
Tools for bolts ' pretension moment value T is design load, and the value of each company is different, under specific mounting process, have specific value.K
tstandard value depend on the bolt of use and the index of cup grease, if solid lubrication cream do not smear or smear little, can k be caused
tbigger than normal, cause the actual pretightning force of bolt to be less than standard pretightning force; Otherwise, if the solid lubrication cream smeared is a lot, will k be made
tless than normal, cause actual pretightning force to be greater than standard pretightning force.Under standard compliant situation smeared by solid lubrication cream, k
tgenerally value between 0.11 to 0.12, sets k here
tstandard value be 0.11, pretightning force directly measures by gasket pressure sensor.
As operating load F according to the same mode of similar sinusoidal curve at F
1-F
2between when fluctuating, accurately can measure the total pulling force of bolt at F
01-F
02between fluctuation.The total pulling force of bolt
in formula: F
0be the total pulling force of bolt, unit is kN; F' is the pretightning force of bolt, and unit is kN; F is the operating load of bolt, and unit is kN; C
1be bolt rigidity, unit is N/m; C
2be the rigidity of the connected piece combination of bolt, unit is N/m.Rigidity is build-in attribute, is determined by material speciality and material shape.
After eliminating bolt quality, no problem such as painting cup grease and tools for bolts ' pretension moment value etc., be fatigue break from its fracture cause of fracture analysis of bolt, the reason that fatigue break occurs is that real-time stress amplitude exceeds standard.
Can draw according to formula (2), the total pulling force amplitude of bolt during unit operation:
And then draw the stress amplitude of bolt:
Can be drawn by formula (4): when operating load initial conditions is constant, the suffered stress amplitude in real time of bolt depends on bolt rigidity C
1with the rigidity C of connected piece
2, after there is gap in connected piece end face, its rigidity C
2reduce, cause stress amplitude σ
aincrease.Formula (4) explains and occurs that the unit in gap is in operational process, real-time stress amplitude σ
amain cause bigger than normal.
The operating load F of bolt is the external load that precalculated bolt and connected piece entirety are subject to, and fluctuates within certain scope.In wind power generating set, it is that wind load and blade are conducted oneself with dignity making a concerted effort of gravity, increases along with the increase of wind load.Standard pretightning force and the standard stress amplitude of bolt all calculate according to prior art.
Described bolt mounting process refers to the process of erection bolt, changes and is arranged on flange face bolt tightening sequence, according to the rule that bolt stress changes, finds best bolted order.
According to designing requirement, such as, when tested object is M30 bolt, stress amplitude, when below 11MPa, can be thought and reach optimum.In general according to the feature of whole flange face stress distribution, repeat just to find best tightening sequence for 3-4 time, if bolt fracture region is more, then can increase multiplicity, to verify Adjustment effect.
Please specifically consult shown in 2, a kind of bolt mounting process Performance Evaluation equipment of using said method, comprise signal input part module, Signal sampling and processing module and human-computer interaction module, wherein: signal input part module comprises independent the strain signal input end, 4 road sign quasi-mode analog quantity input ends and the power circuit that provides driving source to export for strain signal that arrange; Signal sampling and processing module comprises process chip, and power circuit is that described process chip is powered, and 4 road sign quasi-mode analog quantity signal input parts and strain signal input end are connected with process chip by analog to digital conversion circuit; Human-computer interaction module comprises processor, communication interface, operational module and display module, and the output terminal of process chip is connected respectively with processor, communication interface, and operational module is all connected with processor with display module.
Further specifically, the signal of strain signal input end is after programmable amplifier conditioning, and a road is input to described process chip through analog to digital conversion circuit, and another road is direct and process chip is mutual.
Process chip adopts FPGA integrated circuit, and processor adopts X86-based, and communication interface comprises two network interfaces and three USB interface, and operational module comprises action button and tutorial light, and display module adopts LCD display.
This bolt mounting process Performance Evaluation equipment has the function of the bolt load of 12 road strain signals being carried out to online acquisition, storage and analysis, the object of the accurate analog signals of this bolt mounting process Performance Evaluation equipment access 4 road sign is to access running of wind generating set parameter, and in conjunction with running of wind generating set parameter, judge whether bolt is current stressed normal by calculating.According to the bolt load data collected, judge the overall stressing conditions of flange face from the working bolt magnitude of load of diverse location, thus draw flange face whether stress balance conclusion and provide processing scheme.
Please specifically consult shown in Fig. 3-4, new gasket pressure sensor is column type sensor, and its output is
wherein, μ is Poisson ratio, and k is tension gauge factor, be 1.3, E is elastic modulus, and D is cartridge type strain regions external diameter, and d is cartridge type strain regions internal diameter, is 0.In Fig. 4, Rm plays mould compensating resistance, and Rs is sensitivity compensation resistance, and Rot is thermo-compensator, and Ro is zero compensation resistance, and Rp is standardized compensations resistance.This gasket pressure sensor is for diameter M36mm, and range reaches 76T, and relatively existing sensors with auxiliary electrode range 5T ~ 20T has had significant raising.Described gasket pressure sensor can relate to all models of M20 ~ M46.
This bolt mounting process performance estimating method and equipment are not limited only to the load test of Wind turbines pitch variable bearings, driftage bearing bolts, can be applicable to the bolt load test of all flange connection surfaces.
The above; it is only preferred embodiment of the present invention; not do any pro forma restriction to the present invention, those skilled in the art utilize the technology contents of above-mentioned announcement to make a little simple modification, equivalent variations or modification, all drop in protection scope of the present invention.
Claims (7)
1. a bolt mounting process performance estimating method, is characterized in that comprising the following steps:
A. the tightening sequence of each bolt on flange face is determined;
B. while fastening bolt, packing ring pressure transducer is installed between flange face and coupling bolt, after bolted completes, is obtained the distribution of the bolt pretightening on circumference of flange end face by gasket pressure sensor measurement;
C. certain operating load is applied to bolt, the waving interval F of the real-time total pulling force of bolt in test unit running process under different operating load
01-F
02, and calculate the real-time stress amplitude σ of bolt
a, described in
wherein d
cfor the diameter of this bolt;
D. by the real-time stress amplitude σ of all bolts
acompare with its standard stress amplitude, when described real-time stress amplitude is greater than standard stress amplitude, show that the conclusion in gap appears in connected piece end face, and return steps A and determine new bolted order, otherwise determine that current bolted order is for optimum bolted order.
2. bolt mounting process performance estimating method according to claim 1, is characterized in that between described step B, C further comprising the steps of:
The pretightning force of this bolt detected and its standard pretightning force are compared, when described pretightning force is not equal to standard pretightning force, judge whether the quality whether bolt does not smear solid lubrication cream, cup grease and bolt on request has problem, whether the pre-fastening moment value T of setting meets standard, and return the order that step B determines according to steps A again and correct technique and fastening each bolt according to described judgement.
3. bolt mounting process performance estimating method according to claim 1, it is characterized in that described gasket pressure sensor is resistance-type gasket pressure sensor, piezoelectric type gasket pressure sensor or condenser type gasket pressure sensor, described gasket pressure sensor is provided with 8 pasters.
4. application rights requires a bolt mounting process Performance Evaluation equipment for method according to any one of 1-3, it is characterized in that comprising signal input part module, Signal sampling and processing module and human-computer interaction module, wherein:
Described signal input part module comprises independent the strain signal input end, 4 road sign quasi-mode analog quantity input ends and the power circuit that provides driving source to export for strain signal that arrange;
Described Signal sampling and processing module comprises process chip, and described power circuit is that described process chip is powered, and described 4 road sign quasi-mode analog quantity signal input parts and strain signal input end are connected with process chip by analog to digital conversion circuit;
Described human-computer interaction module comprises processor, communication interface, operational module and display module, and the output terminal of described process chip is connected respectively with described processor, communication interface, and described operational module is all connected with processor with display module.
5. bolt mounting process Performance Evaluation equipment according to claim 4, it is characterized in that the signal of described strain signal input end is after programmable amplifier conditioning, one tunnel is input to described process chip through analog to digital conversion circuit, and another road is direct and process chip is mutual.
6. bolt mounting process Performance Evaluation equipment according to claim 4, it is characterized in that described process chip adopts FPGA integrated circuit, described processor adopts X86-based, described communication interface comprises two network interfaces and three USB interface, described operational module comprises action button and tutorial light, and described display module adopts LCD display.
7. bolt mounting process Performance Evaluation equipment according to claim 4, is characterized in that described strain signal is 12.
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|---|---|---|---|
| CN201510295782.0A CN104931185B (en) | 2015-06-02 | 2015-06-02 | Bolt mounting process performance estimating method and equipment |
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| CN104931185B CN104931185B (en) | 2017-08-04 |
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Cited By (5)
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|---|---|---|---|---|
| CN109648504A (en) * | 2019-01-16 | 2019-04-19 | 山东理工大学 | A kind of pre-fastening moment estimating and measuring method of bolt fastener |
| CN111678627A (en) * | 2020-05-21 | 2020-09-18 | 北京交通大学 | Stress test method for shield tunnel segment connecting bolt |
| CN112161731A (en) * | 2020-10-29 | 2021-01-01 | 陕西中科启航科技有限公司 | Online monitoring method for flange bolt tension and working load |
| CN112784402A (en) * | 2020-12-31 | 2021-05-11 | 北京动力机械研究所 | Method for optimizing pre-tightening force of bolt with brittle interlayer structure |
| CN114612419A (en) * | 2022-03-07 | 2022-06-10 | 无锡雪浪数制科技有限公司 | Process detection method based on depth vision and multi-sensor technology |
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|---|---|
| CN104931185B (en) | 2017-08-04 |
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