CN109239198B - Method for detecting transverse crack diffracted wave of main shaft of wind driven generator - Google Patents
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Abstract
The invention discloses a method for detecting diffraction waves of transverse cracks of a main shaft of a wind driven generator, which utilizes a piezoelectric sensor to radiate ultrasonic waves on the end surface of the main shaft in a circular scanning mode, and arranges two cylindrical electromagnetic acoustic sensors on the inner wall of a central hole of the main shaft for receiving the diffraction waves after the ultrasonic waves and the cracks act; respectively establishing an acoustic wave diffraction point elliptical track through the time of diffraction signals received by the two electromagnetic acoustic sensors; and determining the position of the crack tip by using the intersection point of the two elliptical tracks, thereby obtaining the depth of the transverse crack of the main shaft to the axial center and the length of the crack from the end surface of the main shaft. The method detects the transverse cracks of the main shaft through the diffracted waves, and realizes the accurate evaluation of the expansion depth and position of the transverse cracks of the wind driven generator.
Description
Technical Field
The invention relates to a method for detecting diffraction waves of transverse cracks of openings on the circumferential surface of a main shaft of a wind driven generator, and belongs to the field of nondestructive testing.
Background
The wind energy has the advantages of unlimited sources, existing universality, cleanability in development and utilization and the like, and is a new energy power generation mode with the largest application scale at present. Currently, a horizontal axis wind turbine is a mainstream model of world wind power development and mainly comprises three systems of mechanical transmission, electrical and control. The main shaft is used as a core component of a transmission system, directly bears torque transmitted by a support hub, and is a first energy transmission carrier after wind energy is converted into mechanical energy. The main shaft is corroded by severe working conditions such as large temperature difference, strong corrosion, much sand and dust and the like, and is very easy to generate transverse cracks with an opening on the surface under the complex stress action of torque, axial thrust, pneumatic bending moment and the like for a long time, so that the operation safety of the wind turbine generator is seriously threatened, and even safety accidents are caused. The method has the advantages that the quantitative detection is carried out on the main shaft of the fan, and risk control measures are taken in time, so that the key for guaranteeing the operation safety of the main shaft is realized.
The main shaft of the fan is a large-scale revolving body which is composed of a plurality of shaft sections and is provided with a central hole, and the shaft sections are provided with profile characteristics such as circular bead, chamfer, fillet, unloading groove and the like. The complex outline structure and the large size are the main characteristics of the fan main shaft. For crack detection of a main shaft of a fan, the size of the crack relative to the main shaft is small, and positioning and quantitative characterization are difficult; cracks at the contour feature, end face detection is affected by the contour, and echo identification is difficult; the transverse crack is perpendicular to the central axis, and the circumferential surface detection effect is poor. At present, the conventional ultrasonic detection method adopts the end surface and the circumferential surface of a main shaft for flaw detection, but has great limitations, such as: the quantification technology based on the amplitude of the reflected sound wave is low in quantification precision of the small cracks of the main shaft, and the detection process is greatly influenced by human factors; the end face detects transverse cracks, small cracks are easy to miss detection, and the transverse cracks are not sensitive to circumferential detection. The current detection situation that faces at present cannot effectively detect the transverse cracks of the main shaft, and the transverse cracks with shallow openings can be evaluated more accurately.
The invention provides a novel method for detecting diffraction waves by means of the end face and the central hole of a main shaft, aiming at the problem of detecting transverse cracks of the main shaft of a wind driven generator, and the accurate quantitative detection of the crack position and the expansion depth of the main shaft is realized.
Disclosure of Invention
The invention provides a method for detecting a transverse crack of a main shaft by using the characteristics of a crack tip on acoustic wave diffraction. The longitudinal wave piezoelectric sensor is adopted to radiate ultrasonic waves on the end face of the main shaft, and diffracted sound waves are received through the inner wall of the central hole of the main shaft, so that the detection of the transverse cracks of the opening on the circumferential surface of the main shaft is realized. The method can solve the problems that the transverse cracks are difficult to quantify when the end face of the main shaft is detected and the transverse cracks are insensitive when the circumferential face is detected, and can achieve the purpose of more accurate evaluation of the crack positions and the propagation depths. Compared with other methods for detecting shaft workpieces, the method is more favorable for realizing the detection of the transverse cracks with shallow extension depth of the openings on the circumferential surface of the main shaft, and avoids the defects of quantitative cracks of the echo amplitude.
In order to achieve the purpose, the technical scheme adopted by the invention is a wind driven generator spindle transverse crack diffracted wave detection method, and the device required for achieving the detection method comprises an ultrasonic signal excitation source, a longitudinal wave piezoelectric sensor, an electromagnetic sound sensor and signal acquisition equipment, wherein the ultrasonic signal excitation source is connected with the longitudinal wave piezoelectric sensor, the electromagnetic sound sensor is connected with the signal acquisition equipment, and the specific implementation steps of the method comprise:
step one, acquiring full-size parameters of a main shaft of a wind driven generator, and actually measuring the longitudinal wave sound velocity c of the main shaftL. Selecting a center frequency of f and a diameter of DpThe longitudinal wave piezoelectric sensor ensures that the pointing angle of the sensor in the spindle material is less than 5 degrees. Wherein, the range of f is 2.5 MHz-10 MHz; dpIn the range of(10～30)mm。
And step two, designing two cylindrical electromagnetic acoustic sensors according to the diameter d of the central hole of the main shaft. The coil of the electromagnetic acoustic sensor adopts a folding coil, the folding direction is along the cylindrical circumferential direction, and the spacing between the folding coils is
The number of turns of the coil is 10-20 turns. Wherein, the circumferential length of the coil is pi d. The electromagnetic acoustic sensor adopts a cylindrical permanent magnet, and the magnetization direction of the permanent magnet is along the axial direction of the cylinder; respectively arranging two permanent magnets on two sides of a reverse-folded coil, wherein the unlike magnetic poles are opposite, and fixing the relative positions of the coil and the permanent magnets; the outer diameter of the cylindrical permanent magnet is smaller than the size (1-2) mm of the central hole of the main shaft.
And step three, acquiring a spindle detection range, namely an area where cracks are easy to generate. Dividing the detection area into a plurality of small detection area sections (30-70) mm;
step four, obtaining the distance H between the small detection area section boundary and the end face of the main shaft1And H2，H1<H2(ii) a The longitudinal wave piezoelectric sensor is arranged at the end face of the main shaft with the radius of RiThe near surface of the small detection area section is ensured to be radiated to ultrasonic waves.
Fifthly, respectively placing two electromagnetic sound sensors in the center hole of the main shaft, wherein the distances between the electromagnetic sound sensors and the end face of the main shaft are respectively H2And H2A + 20 to 50mm position.
Step six, exciting the longitudinal wave piezoelectric sensor by the excitation source, and recording the excitation starting time t0(ii) a Respectively collecting output signals of two electromagnetic acoustic sensors, and respectively recording diffracted wave arrival time t1And t2。
Step seven, establishing a plane rectangular coordinate system by taking the center point of the end surface of the main shaft as the circle center, the central shaft of the main shaft as an x axis and the radius of the end surface as a y axis; according to the position coordinates F (0, R) of the longitudinal wave piezoelectric sensori) Two electromagnetic acoustic sensors position coordinates
Are constructed separatelyTwo elliptical tracks are established; the two foci of one of the elliptical tracks are F, F respectively1Major axis length of cL×(t1-t0) The two foci of the other elliptical orbit are F, F respectively2Major axis length of cL×(t2-t0)。
Step eight, searching an intersection point of the two elliptical tracks on the two elliptical tracks obtained in the step seven; the intersection point with a large y value was defined as the crack tip diffraction point P (x)p,yp)。
Step nine, the position of the transverse crack in the main shaft passes through the P point abscissa xpRepresents; on the basis of the distance end face x, the distance end face x is obtainedpRadius of cross section of main shaft at position RcThrough Rc-ypAnd calculating to obtain the crack propagation depth.
Step ten, the radius of the end surface of the main shaft is RiThe position and the expansion depth of the transverse crack in different circumferential directions of the main shaft are obtained according to the six-step to the nine-step moving longitudinal wave piezoelectric sensor.
Eleven, adjusting the scanning radius R of the longitudinal wave piezoelectric sensor on the end face of the main shaft according to the positions of different small detection area sectionsiAnd repeating the fourth step to the tenth step until all the small region segments are detected.
The crack position and the propagation depth are determined by utilizing the sound paths from the crack tip diffraction sound waves to the two electromagnetic sound sensors, namely, the diffraction wave sound path corresponding to the diffraction wave in one time, so that an elliptical track is determined; a second diffracted wave sound path corresponding to another time of the diffracted wave, thereby determining a second elliptical trajectory; the intersection point of the two tracks is the diffraction point of the crack tip; the horizontal coordinate of the diffraction point determines the position of a main shaft where the crack is located, and the vertical coordinate determines the depth position to which the crack extends towards the axis;
the adopted method utilizes a longitudinal wave piezoelectric sensor to radiate sound waves on the end face of the main shaft and utilizes an electromagnetic sound sensor to receive signals in the center hole of the main shaft.
Compared with the prior art, the invention has the following beneficial effects.
1. The invention provides an effective detection means for the transverse cracks of the opening on the surface of the main shaft of the wind driven generator by utilizing the diffraction characteristic of the crack tip to the sound wave; meanwhile, the positions and the expansion depths of the cracks are detected by utilizing the arrival time of the diffracted waves, so that the defect of evaluating the equivalent weight of the cracks by using the amplitude of the echo is overcome.
2. The detection method for radiating ultrasonic waves on the end face of the main shaft and receiving the diffraction signal of the crack tip on the inner wall of the central hole of the main shaft, which is provided by the invention, is sensitive to the detection of small cracks growing on the circumferential outer surface of the main shaft of the wind driven generator, and solves the problem that the conventional detection method is insensitive to the detection of the cracks on the end face and the circumferential surface of the main shaft.
Drawings
FIG. 1 is a schematic illustration of the present invention evaluating crack location and propagation depth;
FIG. 2 illustrates the spindle size and the detection area detected by the embodiment of the present invention;
FIG. 3 is an electromagnetic acoustic sensor designed in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of a sensor arrangement and acoustic beam coverage in an embodiment of the present invention;
FIG. 5 is a time domain waveform collected by an electromagnetic acoustic sensor in an embodiment of the present invention;
FIG. 6 is the crack location and propagation depth achieved by an embodiment of the present invention;
in the figure: 1-longitudinal wave piezoelectric sensor; 2-elliptic locus 1 determined by diffracted wave; 3-opening transverse cracks on the surface; 4-an elliptical trajectory determined by the diffracted waves 2; 5, a main shaft of the wind driven generator; 6-main shaft center line; 7-electromagnetic acoustic sensor; 8-cylindrical permanent magnet; 9-turn-back coil
Detailed Description
The invention is described in detail below with reference to the drawings and the detailed description.
In the long-term service process of the wind driven generator, transverse cracks with openings on the surface are easily generated on the circumferential surface of the main shaft, the cracks directly threaten the operation safety of the main shaft, and the quality of the main shaft can continuously meet the use requirements and needs to be verified by means of nondestructive testing.
The main shaft of the wind driven generator adopted in the embodiment is the main shaft 5 to be measured in fig. 1, the main shaft is made of 42CrMo4, the structure of the main shaft is shown in fig. 2, and a surface opening transverse crack 3 with the depth of 5mm exists at a position 121.60mm away from the end face of the main shaft. The detection surface is the side end surface of the main shaft flange and the inner wall of the central hole.
The equipment adopted by the embodiment comprises 1 ultrasonic signal excitation source, 2 longitudinal wave piezoelectric sensors, 2 electromagnetic acoustic sensors and 1 signal acquisition device, and the specific implementation steps are as follows:
step one, acquiring full-size parameters of a main shaft of the wind driven generator, as shown in figure 2. Actually measuring the ultrasonic longitudinal wave velocity c of the main shaftL5790 m/s. Selecting 2 centers with a frequency of 5MHz and a diameter DpThe radiation angles of 20mm longitudinal wave piezoelectric transducers were 0 ° and 8 °, respectively, and the pointing angle of the longitudinal wave piezoelectric transducer in the principal axis was 4.05 °.
And step two, designing two cylindrical electromagnetic acoustic sensors according to the diameter d of the central hole of the main shaft being 40mm, as shown in fig. 3. The coil of the electromagnetic acoustic sensor adopts a folding coil 9, the folding direction is along the cylindrical circumferential direction, the distance between the folding coils is W which is 0.58mm, and the number of folding cycles is 20. The coil circumferential length was 125.60 mm. The electromagnetic acoustic sensor adopts a cylindrical permanent magnet 8, and the magnetization direction of the permanent magnet is along the direction of a cylindrical axis; respectively arranging two permanent magnets 8 on two sides of a reverse-folded coil 9, enabling unlike magnetic poles to be opposite, and fixing the relative positions of the coil and the permanent magnets; outer diameter D of cylindrical permanent magnetM＝38mm。
And step three, a crack high-incidence part is arranged in a range of 100-170 mm away from the end face, and the area is a detection area, as shown in figure 2. The detection area is divided into 2 small detection area sections, which are respectively A (100-130) mm and B (130-170) mm.
Step four, detecting the distance H between the boundary of the area A and the end face of the spindle1100mm and H 2130 mm; the longitudinal wave piezoelectric sensor 1 with the radiation angle of 0 degree is arranged on the radius R of the end surface of the main shaft1Since the longitudinal wave piezoelectric transducer has a 4.05 ° divergence angle on a circumference of 90mm, it is ensured that the near surface of the (100-130) mm region section can be irradiated with ultrasonic waves, as shown in fig. 4.
And fifthly, respectively placing the two first electromagnetic acoustic sensors and the two second electromagnetic acoustic sensors 7 in the central holes, wherein the distances between the two first electromagnetic acoustic sensors and the two second electromagnetic acoustic sensors and the end face of the main shaft are respectively 130mm and 150mm, as shown in fig. 4.
Step six, exciting the longitudinal wave piezoelectric sensor by adopting an ultrasonic signal excitation source, and recording the excitation starting time t 00 μ s; respectively acquiring output signals of the first electromagnetic acoustic sensor and the second electromagnetic acoustic sensor by adopting signal acquisition equipment, and respectively recording the arrival time t of the diffracted waves132.54 μ s and t233.41 mus, as shown in fig. 5.
Step seven, as shown in fig. 6, a plane rectangular coordinate system is established by taking the center point of the end surface of the main shaft as the center of a circle O, the central shaft 6 of the main shaft as the x axis and the radius of the end surface as the y axis; according to the position coordinates F (0,90) of the longitudinal wave piezoelectric sensor and the position F of the first electromagnetic acoustic sensor1(130,20) second electromagnetic acoustic sensor position F2(150,20) respectively establishing two elliptical trajectories; two focuses of one elliptical track 2 are respectively F (0,90) and F1(130,20) the major axis length is 188.41mm, and two foci of another elliptical orbit 4 are F (0,90) and F respectively2(150,20) and the length of the long axis is 193.44 mm.
Step eight, acquiring intersection points of the two elliptical tracks on the two elliptical tracks obtained in the step seven, wherein the coordinates are P1(122.90,85.03),P2(133.10, -4.82). Intersection point P with large y value1(122.90,85.03), recorded as crack tip diffraction point.
Step nine, the position of the transverse crack in the main shaft passes through P1Point abscissa xp122.90 mm; on the basis of the distance end face x, the distance end face x is obtainedpRadius R of the cross section of the main shaft at the position of 122.90mmcAt 89.36mm, a crack propagation depth of 4.33mm was determined, as shown in fig. 6.
Step ten, the radius of the end surface of the main shaft is R1A 90mm circle moves the longitudinal wave piezoelectric transducer. And testing the position and the propagation depth of the transverse crack at the position where the diffraction signal appears according to the sixth step to the ninth step.
Step eleven, aiming at the detection area B, detecting by adopting the longitudinal wave piezoelectric sensor 1 with the radiation angle of 8 degrees and detecting the longitudinal wave piezoelectric sensorPosition adjusted to radius R2On a scanning circle of 65mm, as shown in fig. 4. The sensor has a diffusion angle of 4.05 degrees, so that the near surface of a detection area B (130-170) mm can be ensured to be radiated by ultrasonic waves.
And step twelve, adjusting the position of the electromagnetic acoustic sensor in the center hole of the main shaft to be 170mm and 190mm away from the end face of the main shaft respectively.
Step thirteen, according to the method from step six to step ten, testing the crack position and the expansion depth in the detection area B until the longitudinal wave piezoelectric sensor is at the radius R2Scanning is completed on the detection path of 65 mm.
Claims (3)
1. A method for detecting transverse crack diffracted waves of a main shaft of a wind driven generator is characterized by comprising the following steps: the device required for realizing the detection method comprises an ultrasonic signal excitation source, a longitudinal wave piezoelectric sensor, an electromagnetic sound sensor and a signal acquisition device, wherein the ultrasonic signal excitation source is connected with the longitudinal wave piezoelectric sensor, the electromagnetic sound sensor is connected with the signal acquisition device, the method comprises the following concrete implementation steps,
step one, acquiring full-size parameters of a main shaft of a wind driven generator, and actually measuring the longitudinal wave sound velocity c of the main shaftL(ii) a Selecting a center frequency of f and a diameter of DpThe longitudinal wave piezoelectric sensor ensures that the pointing angle of the sensor in the main shaft material is less than 5 degrees; wherein, the range of f is 2.5 MHz-10 MHz; dpThe range of (1) is (10-30) mm;
secondly, designing two cylindrical electromagnetic acoustic sensors according to the diameter d of the central hole of the main shaft; the coil of the electromagnetic acoustic sensor adopts a folding coil, the folding direction is along the cylindrical circumferential direction, and the spacing between the folding coils is
The number of turns of the coil is 10-20 turns; wherein, the circumferential length of the coil is pi d; the electromagnetic acoustic sensor adopts a cylindrical permanent magnet, and the magnetization direction of the permanent magnet is along the axial direction of the cylinder; respectively arranging two permanent magnets on two sides of a reverse-folded coil, wherein the unlike magnetic poles are opposite, and fixing the relative positions of the coil and the permanent magnets; cylindrical shapeThe outer diameter of the permanent magnet is smaller than the size (1-2) mm of the central hole of the main shaft;
step three, obtaining a spindle detection range, namely an area where cracks are easy to generate; dividing the detection area into a plurality of small detection area sections (30-70) mm;
step four, obtaining the distance H between the small detection area section boundary and the end face of the main shaft1And H2，H1<H2(ii) a The longitudinal wave piezoelectric sensor is arranged at the end face of the main shaft with the radius of RiOn the circumference of the small detection area section, the near surface of the small detection area section can be ensured to be radiated by ultrasonic waves;
fifthly, respectively placing two electromagnetic sound sensors in the center hole of the main shaft, wherein the distances between the electromagnetic sound sensors and the end face of the main shaft are respectively H2And H2A + 20-50 mm position;
step six, exciting the longitudinal wave piezoelectric sensor by the excitation source, and recording the excitation starting time t0(ii) a Respectively collecting output signals of two electromagnetic acoustic sensors, and respectively recording diffracted wave arrival time t1And t2；
Step seven, establishing a plane rectangular coordinate system by taking the center point of the end surface of the main shaft as the circle center, the central shaft of the main shaft as an x axis and the radius of the end surface as a y axis; according to the position coordinates F (0, R) of the longitudinal wave piezoelectric sensori) Two electromagnetic acoustic sensors position coordinates
Respectively establishing two elliptical tracks; the two foci of one of the elliptical tracks are F, F respectively1Major axis length of cL×(t1-t0) The two foci of the other elliptical orbit are F, F respectively2Major axis length of cL×(t2-t0)；
Step eight, searching an intersection point of the two elliptical tracks on the two elliptical tracks obtained in the step seven; the intersection point with a large y value was defined as the crack tip diffraction point P (x)p,yp)；
Step nine, the position of the transverse crack in the main shaft passes through the P point abscissa xpRepresents; on the basis of this, obtainGet a distance end surface xpRadius of cross section of main shaft at position RcThrough Rc-ypCalculating to obtain the crack propagation depth;
step ten, the radius of the end surface of the main shaft is RiThe position and the expansion depth of the transverse crack in different circumferential directions of the main shaft are obtained according to the six-step to the nine-step moving longitudinal wave piezoelectric sensor;
eleven, adjusting the scanning radius R of the longitudinal wave piezoelectric sensor on the end face of the main shaft according to the positions of different small detection area sectionsiAnd repeating the fourth step to the tenth step until all the small region segments are detected.
2. The method for detecting the transverse crack diffracted wave of the main shaft of the wind driven generator as claimed in claim 1, wherein the method comprises the following steps: the crack position and the propagation depth are determined by utilizing the sound paths from the diffracted sound waves of the crack tip to the two electromagnetic sound sensors respectively, namely, the diffracted wave sound path corresponding to one time of the diffracted wave, so that an elliptic track is determined; a second diffracted wave sound path corresponding to another time of the diffracted wave, thereby determining a second elliptical trajectory; the intersection point of the two tracks is the diffraction point of the crack tip; the abscissa of the diffraction point determines the position of a main shaft where the crack is located, and the ordinate determines the depth position to which the crack extends towards the axis.
3. The method for detecting the transverse crack diffracted wave of the main shaft of the wind driven generator as claimed in claim 1, wherein the method comprises the following steps: the adopted method utilizes a longitudinal wave piezoelectric sensor to radiate sound waves on the end face of the main shaft and utilizes an electromagnetic sound sensor to receive signals in the center hole of the main shaft.
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| CN111707735B (en) * | 2020-05-14 | 2023-08-18 | 北京工业大学 | Method for quantifying transverse cracks of fan spindle by using dual-mode diffraction waves |
| CN111579646B (en) * | 2020-05-29 | 2021-07-06 | 中国地质大学（北京） | In-situ nondestructive testing method for stone cultural relic fracture |
| CN113092581B (en) * | 2021-03-09 | 2023-09-22 | 北京工业大学 | Method for quantifying transverse cracks on surface of main shaft by using position of central hole of main shaft of wind driven generator |
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Effective date of registration: 20220811 Address after: No. 636, Beikou Comprehensive Building, Baiguang Road, Xicheng District, Beijing 100053 Patentee after: BEIJING ZHONGTANGDIAN ENGINEERING CONSULTING Co.,Ltd. Address before: 100124 No. 100 Chaoyang District Ping Tian Park, Beijing Patentee before: Beijing University of Technology |