CN110879912A - Fatigue analysis method and device - Google Patents
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- CN110879912A CN110879912A CN201811034153.2A CN201811034153A CN110879912A CN 110879912 A CN110879912 A CN 110879912A CN 201811034153 A CN201811034153 A CN 201811034153A CN 110879912 A CN110879912 A CN 110879912A
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Abstract
The invention discloses a fatigue analysis method and a fatigue analysis device based on operation data, wherein the method comprises the steps of determining the load cycle of a structural component based on the load characteristic representation of the structural component and historical operation data in a specified time period; determining the stress period of a designated area on the structural component by taking the load period as a boundary condition; and determining a fatigue indicating parameter of the structural component at the inspection time based on the stress cycle. By adopting the technical scheme of the invention, the residual service life of the structural component and the maintenance plan can be adjusted according to the actual operation condition according to the specified period, so that a user can reasonably use the equipment conveniently, and the use cost of the equipment is reduced.
Description
Technical Field
The invention relates to the field of mechanical analysis, in particular to a fatigue analysis method and device for a structural component.
Background
The Gas Turbine (Gas Turbine) is an internal combustion type power machine which takes continuously flowing Gas as a working medium to drive an impeller to rotate at a high speed and converts the energy of fuel into useful work, and is a rotary impeller type heat engine.
Currently, predictive maintenance methods applied to gas turbines are implemented primarily using state data or trends (e.g., vibration, noise, temperature, etc.) of the equipment at a single point in time. By analyzing the abnormal trend or sudden change of the related data, some local defects or faults can be detected, and further maintenance can be carried out before serious damage occurs.
Disclosure of Invention
Aiming at the problem that the state of equipment/components cannot be accurately evaluated, the invention provides a method and a device capable of determining fatigue indicating parameters of the equipment/components according to actual operation data.
The invention provides a fatigue analysis method of a structural component on one hand, which comprises the following steps: determining a load cycle of the structural component based on the load signature representation of the structural component and historical operating data over a specified time period; determining a stress cycle of a designated area on the structural component with the load cycle as a boundary condition; and determining a fatigue indicating parameter of the structural component at the moment of inspection based on the stress cycle. By the fatigue analysis method, the current state can be determined based on the actual operation data of the structural component, and further the fatigue indication parameter of the structural component can be determined.
In one embodiment, the specified time period corresponds to a time period in which the structural component has been operated prior to the inspection time; or the specified time period corresponds to a sub-time period in a time period in which the structural component has been operated before the inspection time. By this embodiment, it is possible to flexibly determine from which piece of historical operating data the fatigue indicating parameter is calculated, depending on the operating conditions of the structural component.
In one embodiment, the load characteristic representation is associated with an operating parameter of the structural component, wherein the load characteristic representation comprises a mechanical load characteristic representation and/or a thermal load characteristic representation. The operating parameters in this embodiment are known or are convenient to measure during operation of the device/structural component.
In one embodiment, the designated area includes: a first region that affects a lifetime of the structural component to a greater extent than a non-first region. The first region further includes: a second region having a degree of duty cycle variation greater than a specified threshold. By the implementation mode, the stress period can be determined according to which areas need to be calculated, and the complexity of data processing is simplified.
In one embodiment, the fatigue-indicating parameter comprises a remaining life of the structural component determined based on a specified operating cycle. This embodiment determines the effect of the fatigue indicating parameter.
In one embodiment, the number of specified operating cycles performed by the structural component before the next maintenance of the structural component is determined based on the specified operating cycle and the fatigue indicating parameter. This embodiment provides how to determine the time for the next maintenance.
In one embodiment, the specified operation cycle is a standard operation cycle or a non-standard operation cycle determined according to historical operation data in the specified time period. The embodiment provides a basis for determining the time of the next maintenance, namely the time of the next maintenance can be flexibly determined according to the actual operation condition according to the standard operation period and the nonstandard operation period.
In another aspect, the present invention provides a fatigue analysis device for a structural member, including: a duty cycle calculation module configured to determine a duty cycle of the structural component based on the load signature representation of the structural component and historical operating data over a specified time period; a stress cycle calculation module configured to determine a stress cycle of a specified region on the structural component with the load cycle as a boundary condition; and a fatigue calculation module configured to determine a fatigue indication parameter of the structural component at an inspection time based on the stress cycle.
In another aspect, the present invention also provides a computer storage medium having stored thereon computer-executable instructions that, when executed, perform the aforementioned method.
In another aspect, the present invention further provides a computer device, which includes a memory and a processor, wherein the memory stores computer-executable instructions, and when the executable instructions are executed, the processor executes the method described above.
Yet another aspect of the invention proposes a computer program product, tangibly stored on a computer-readable medium and comprising computer-executable instructions that, when executed, cause at least one processor to perform the method as described above.
By adopting the technical scheme of the invention, the residual service life of the structural component and the maintenance plan can be adjusted according to the actual operation condition according to the specified period, so that a user can reasonably use the equipment conveniently, and the use cost of the equipment is reduced. In addition, the invention also provides a scheme for flexibly adjusting the service life curve, and simplifies the complexity of data collection and analysis.
Drawings
Embodiments are shown and described with reference to the drawings. These drawings are provided to illustrate the basic principles and thus only show the aspects necessary for understanding the basic principles. The figures are not to scale. In the drawings, like reference numerals designate similar features.
FIG. 1 is a flow chart of a method of fatigue analysis of a structural component in accordance with one embodiment of the present invention;
FIG. 2 is a graph illustrating theoretical life curves for a structural component in accordance with one embodiment of the present invention;
FIG. 3 is a graph illustrating a modified life curve of a structural component in accordance with one embodiment of the present invention;
fig. 4 is a schematic diagram of a fatigue analysis apparatus according to an embodiment of the invention.
Detailed Description
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof. The accompanying drawings illustrate, by way of example, specific embodiments in which the invention may be practiced. The illustrated embodiments are not intended to be exhaustive of all embodiments according to the invention. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate.
First, terms related to the present invention will be explained. The load comprises a force load and a heat load; the duty cycle refers to the relationship between load (which refers to mechanical load and thermal load) and time, wherein the mechanical load refers to airflow pressure, centrifugal force and other acting force of components on the structural component, and the thermal load refers to the surface temperature, surface heat flux and the like of the structural component.
Through extensive practice, the inventors found that the current methods for fatigue analysis and predictive maintenance of mechanical components are mainly based on state data or trend data (e.g., vibration, noise, temperature, etc.) of the mechanical components at a single point in time, and by analyzing abnormal or sudden changes of the data, it is possible to determine which parts of the mechanical components are defective or malfunctioning, and then perform maintenance before severe damage occurs.
However, the current method mainly analyzes current state data or trend data to determine the current state or the future maintenance time of the mechanical component, and since the operation state of each mechanical component is different, the future maintenance time is determined based on the current state only, and the mechanical component cannot be properly maintained accurately. This is especially true for integrated machine components (e.g., gas turbines), where it is difficult to accurately predict the maintenance time of the machine component or parts thereof.
Based on the above problems, the present invention provides a method for performing fatigue analysis on a mechanical component based on data of the mechanical component during the whole operation period, thereby determining a fatigue indicating parameter of the mechanical component. It will be appreciated that the fatigue indicating parameter is representative of a current degree of fatigue of the structural component determined based on historical usage, for example, the fatigue indicating parameter may include a remaining usable time (i.e., remaining life) of the current component.
The fatigue analysis method proposed by the present invention will be explained below by taking a gas turbine as an example.
During operation of the gas turbine, relevant parameters that can be used to determine a fatigue-indicative parameter of the gas turbine are measured and collected, which in turn is used to determine a fatigue-indicative parameter of a component in the gas turbine by fatigue analysis. Exemplary measured historical operating data corresponds to a specified operating period (e.g., an entire operating period of the gas turbine), including inlet gas data, operational control data (e.g., start-up and shut-down times, start-up/shut-down speeds, temperatures, metal temperatures), and power output data. It will be appreciated that the content of the historical operating data may be determined in accordance with the method of calculating the fatigue indicative parameter of the component to be analysed, for example the measurement data may comprise data provided by sensors located at specified locations.
Referring to fig. 1, fig. 2 and fig. 3, fig. 1 is a flowchart illustrating a fatigue analysis method for a structural member according to an embodiment of the invention.
Step S101: based on the specified operating parameters, a load signature representation of the structural component and a theoretical life of the structural component are determined.
In this step, the specified operation parameters may include materials, shapes, operation environments, operation states, and the like of the structural members. In the present embodiment, the operating parameters may be known (e.g., material, shape of the structural component) or may be directly measured (e.g., operating environment, state of the structural component, etc.) in the case of operation of the structural component. Through testing or modeling simulations of the structural component, the relationship between the load signature and the operating parameters of the structural component may be determined. In this embodiment, the characterization of the load may be used to calculate a duty cycle on the structural component, such as a mechanical duty cycle and/or a thermal duty cycle.
For example, if the structural member is a rotating member, the centrifugal force can be directly calculated from the rotational speed, and therefore the centrifugal force of each region on the structural member can be represented by the rotational speed of the region. Therefore, although the centrifugal force cannot be directly measured, the centrifugal force can be obtained by measuring the rotational speed of the structural member. It is understood that the structural component analyzed herein is any structural component that may be in a gas turbine.
Similarly, the air pressure and surface temperature of the structural component may be measured during testing, and a characteristic representation of the load determined by modeling (e.g., curve fitting to the data). By multipoint sampling the structural component, the relationship between the load and the relevant parameters of each region on the structural component can be determined, and further the load characteristic representation of the component can be determined, which can be expressed as:
L＝f1(position,time since startup,speed,air flux,gas flux,poweroutput,ambient temperature,ambient humidity) (1)
wherein L is the load of the structural component, position is the position of each region on the structural component, time position is the running time of the structural component from start to present, speed is the current rotating speed of the structural component, air flux is the air flow, power output is the power output, ambient temperature is the ambient temperature, ambient humidity is the ambient humidity. It is understood that the above parameters are only examples, different components and parameters required to be measured may be different, and those skilled in the art can select corresponding parameters according to specific applications, and need not be listed here.
From the load characterization of the structural component, a theoretical life curve S1 for the structural component at the standard operating cycle may be determined, as shown in fig. 2. In other words, the slope of the curve S1 is determined based on the degree of influence of the standard operating cycle on the life.
Step S102: a load cycle of the structural component is determined based on the load signature representation of the structural component and historical operating data over a specified time period.
In this step, the load on the specified component is determined based on historical operating data associated with the component, and the relationship of the load to the operating data, i.e., the load cycle represents the time-varying load on the structural component, is determined. The historical operating data here corresponds to data that can be used to determine the duty cycle of a structural component during a period of time in which the structural component has been operating.
Since the load signature representation is determined based on historical operating data associated with the component, the load signature representation may characterize the relationship between the load on the component and the operating data, as shown in expression 2:
LC＝f2(position,t)＝f1(position,operation data) (2)
wherein LC represents a duty cycle on the structural component, position is an area position on the structural component, and operation data is operation data of the structural component, and may include one or more of the following parameters: time startup, speed, air flux, gas flux, power output, ambient temperature, and ambient humidity.
Step S103: the stress cycle of a designated area on the structural component is determined with the load cycle as a boundary condition.
The stress cycle refers to the relationship between stress on the given component and time. In this step, the stress cycle of the designated region of the part is determined with the load cycle as a boundary condition of the analytical model. It will be appreciated that the designated area may include a key area or other designated area.
In one embodiment, the critical area affects the life of the structural component to a greater extent than the non-critical area affects the life of the structural component. The critical area may be determined based on typical loading conditions (e.g., a fracture prone area on the structural component), i.e., the critical area has a greater lifetime impact on the structural component than the non-critical area. In addition, the critical regions may also include regions where the stress cycle varies too much. For example, when the degree of change of the stress cycle (e.g., the amplitude of the stress cycle becoming larger, the frequency of the change of the stress cycle) of a certain region on the structural member exceeds a threshold value, or the number of times of exceeding the threshold value reaches a predetermined value, the stress cycle of the certain region needs to be observed. It will be appreciated that the selection and setting of the threshold may be set according to the specific application.
From the above, the critical areas in this step correspond to one or more locations on the structural component. In one embodiment, the critical area has a greater impact on the life of the structural component than the non-critical area.
When taking a Finite Element Analysis (FEA) model as an example, a load cycle is taken as a boundary condition of the FEA model, and then transient analysis is performed by using the FEA model, so as to determine a stress cycle of a critical region of a structural component, as shown in expression (3):
SC＝f3(criticalspot,LC) (3)
where SC is the stress period, criticalspot is the location of the critical area, and LC is the duty cycle of the structural component.
Step S104: based on the stress period, a fatigue-indicative parameter of the structural component at the moment of inspection is determined.
In this step, with the stress cycle of the structural component, a fatigue indicating parameter of the component may be calculated based on the damage accumulation, e.g. using the Miner model. Specifically, since the theoretical life of the structural member is determined in step S101, in this step, the life curve of the structural member in the current state will be obtained based on the fatigue indicating parameter determined from the actual value of the stress cycle.
FIG. 3 is a schematic diagram of a current lifetime curve and a theoretical lifetime curve according to an embodiment of the present invention.
In actual use of the structural component, the actual life of the structural component is different from the theoretical life due to different operation conditions. The determination of the remaining life of the structural component is explained below in terms of the effect of the operating cycle on the life of the structural component.
(1) The structural component is operated in overload before time T (inspection time)
In this case, the load of the structural member is excessive. Between 0 and T, the degree of influence of the operating cycle experienced by the structural component on the life of the structural component is greater than the degree of influence of the standard operating cycle on the life of the structural component. The fatigue indication parameter at the time T can be determined by calculating the historical operating data from 0 to T. In one embodiment, the determined fatigue-indicating parameter comprises a remaining usable time (i.e. a theoretical remaining life) of the current structural component. It will be appreciated that in other embodiments, the fatigue-indicating parameter may also include other parameters associated with the degree of fatigue of the current structural component, not to mention here.
For an overload operated structural component, its remaining life may be lower than the theoretical life at time T, i.e., at time T, the life curve S2 is below the curve S1. It will be appreciated that by operating under excess load, the life of the structural components will be reduced. Since the present embodiment is measured by a standard operation cycle, the slope of the curve S2 after the time T coincides with the slope of the theoretical life curve S1. In addition, based on the slope of S2 between 0 and T, the influence of the previous operation state on the service life of the structural component can be determined, and the user can conveniently make corresponding improvement at the later stage.
(2) Low-load operation of structural component before time T
If the structure is operating at a low load, such as a light load all the time, or is shut down for a long period of time, before time T, it can be determined that the remaining life of the structural component will be higher than the remaining life at time T by calculating the historical operating data from time 0 to time T, and the life curve S3 can be determined.
As can be seen from the above, in the process of determining the remaining life at time T, the present embodiment uses the operation data of the structural component between times T, so that the state of the structural component can be reflected more truly and accurately.
Step S105: the number of standard operating cycles performed before the next maintenance is determined based on the updated life curve.
In this step, a safety factor is determined based on the corrected life curve and the effect of the standard operating cycle on the life curve. For example, it is determined that there may be 30 standard operating cycles before the next maintenance, and to avoid the risk due to uncertainty or calculation, a safety factor of 1.5 may be set, so that the user may be alerted or maintenance may be automatically started after the 20 th standard operating cycle is over.
It is understood that when the actual operating conditions are different from the standard operating cycle, such as too long a shutdown or too long a high load operation, the corresponding load cycle will also change, and the life curve S2/S3 will be further modified.
In one embodiment, the life curve may also be determined based on the non-standard operating cycles determined from historical operating data prior to the inspection time T, thereby determining the number of non-standard operating cycles performed by the structural component before the structural component is subjected to the next maintenance.
In one embodiment, if the structural component operates regularly, the duty cycle can also be determined from the operating data for a specific time period, i.e. a non-standard operating cycle is determined. In addition, the operation of the structural component between 0 and T conforms to certain regularity, and the fatigue indication parameter at the T moment can be determined according to one or more sub-time periods of 0 to T1, T1 to T2 and T2 to T, so that the collection of historical operation data of the structural component can be reduced. It is understood that the non-standard operation cycle may be a user-defined operation cycle.
Therefore, the invention can adjust the residual service life of the structural component and the maintenance plan based on the appointed period according to the actual operation condition, is convenient for users to reasonably use the equipment and reduces the use cost of the equipment. For example, the lifetime curves S2/S3 may be updated daily, weekly, or at specified intervals to obtain lifetime curves that reflect actual operating data. It will be appreciated that the above-described updates may actually be determined based on the particular analysis object.
Fig. 4 is an architecture diagram of a fatigue indication parameter analyzing apparatus according to an embodiment of the present invention, wherein the apparatus 400 comprises:
a) a signature analysis module 410 configured to determine a load signature representation and a theoretical life of the structural component based on the test data;
b) a duty cycle calculation module 420 configured to determine a duty cycle of the structural component based on the characterization representation and the historical operating data;
c) a stress cycle calculation module 430 configured to determine a stress cycle of the structural component based on the load cycle;
d) a fatigue calculation module 440 configured to determine a fatigue indication parameter based on the stress period.
In particular, the signature analysis module 410 may determine a load signature representation of the structural component associated with the operating parameter from either the acquisition of experimental data or modeling simulations and output the load signature representation. The duty cycle calculation module 420 determines the duty cycle of the structural component at the current time based on the load signature representation and the obtained historical operating data of the structural component. In the present embodiment, the historical operating data includes operating data of the structural component prior to the current time. The stress cycle calculation module 430 determines the stress cycle of a specified region of the structural component based on the current load cycle of the structural component. It is to be understood that the designated area may be a key area determined according to typical load conditions, or an area designated by a user, or an area in which variation in a load cycle is large.
The fatigue calculation module 440 determines the fatigue-indicating parameter based on the stress cycle. Based on the fatigue-indicating parameter, the fatigue calculation module 440 may also determine a next maintenance time for the structural component based on the standard operating cycle.
In one embodiment, the signature analysis module 410 may also determine a load signature from the obtained measurement data regarding the operation of the structural component. For example, by obtaining the air pressure and surface temperature of the structural component, a model can be constructed to determine a characteristic representation of the load of the structural component.
The flow of the fatigue analysis method in fig. 1 also represents computer readable instructions comprising a program executed by a processor. The program may be embodied in a tangible computer readable medium such as a CD-ROM, floppy disk, hard disk, Digital Versatile Disk (DVD), blu-ray disk, or other form of memory. Alternatively, some or all of the steps in the example method of fig. 1 may be implemented using any combination of Application Specific Integrated Circuits (ASICs), Programmable Logic Devices (PLDs), field programmable logic devices (EPLDs), discrete logic, hardware, firmware, etc. The information may be stored on the readable medium at any time. It will be appreciated that the computer readable instructions may also be stored on a cloud platform in a web server for ease of use by a user.
The invention also provides a computer device which comprises a processor and a memory. The memory is to store instructions that, when executed, cause the processor to perform the fatigue analysis method of fig. 1. For example, the specification, when executed, causes the processor to: determining a load cycle of the structural component based on the load signature representation of the structural component and historical operating data over a specified time period; determining a stress cycle of a designated area on the structural component with the load cycle as a boundary condition; and determining a fatigue indicating parameter of the structural component at the moment of inspection based on the stress cycle. The fatigue analysis method can determine the current state based on the actual operation data of the structural component, and further determine the fatigue indication parameter of the structural component.
Another aspect of the invention also proposes a computer program product, tangibly stored on a computer-readable medium and comprising computer-executable instructions that, when executed, cause at least one processor to perform the method of fatigue analysis in fig. 1.
While the invention has been illustrated and described in detail in the drawings and foregoing description with reference to preferred embodiments, the invention is not limited to the embodiments disclosed, and other arrangements derived therefrom by those skilled in the art are within the scope of the invention.
Claims (19)
1. A method for analyzing fatigue of a structural member, comprising:
determining a load cycle of the structural component based on the load signature representation of the structural component and historical operating data over a specified time period;
determining a stress cycle of a designated area on the structural component with the load cycle as a boundary condition; and
determining a fatigue-indicating parameter of the structural component at the inspection time based on the stress cycle.
2. The method of claim 1,
the specified time period corresponds to a time period in which the structural component has been operated before the inspection time; or
The specified time period corresponds to a sub-time period in a time period in which the structural component has been operated before the inspection time.
3. The method of claim 1, wherein the load signature is associated with an operating parameter of the structural component, wherein the load signature comprises a mechanical load signature and/or a thermal load signature.
4. The method of claim 1, wherein the designating the region comprises:
a first region that affects a lifetime of the structural component to a greater extent than a non-first region.
5. The method of claim 4, wherein the first region further comprises:
a second region having an increased magnitude of stress cycle greater than a first threshold and/or a frequency of stress cycle variation greater than a second threshold.
6. The method of claim 1, wherein the fatigue-indicating parameter comprises a remaining life of the structural component determined based on a specified operating cycle.
7. The method of claim 6,
determining, based on the specified operating cycle and the fatigue indicating parameter, a number of times the structural component performs the specified operating cycle before a next maintenance of the structural component.
8. The method of claim 7, wherein the specified operating period is a standard operating period or a non-standard operating period determined from historical operating data over the specified time period.
9. A fatigue analysis device for a structural member, comprising:
a duty cycle calculation module configured to determine a duty cycle of the structural component based on the load signature representation of the structural component and historical operating data over a specified time period;
a stress cycle calculation module configured to determine a stress cycle of a specified region on the structural component with the load cycle as a boundary condition; and
a fatigue calculation module configured to determine a fatigue-indicating parameter of the structural component at an inspection time based on the stress cycle.
10. The apparatus of claim 9,
the specified time period corresponds to a time period in which the structural component has been operated before the inspection time; or
The specified time period corresponds to a sub-time period in a time period in which the structural component has been operated before the inspection time.
11. The apparatus of claim 9, further comprising:
a feature analysis module configured to determine the load signature based on an operating parameter of the structural component, wherein the load signature comprises a mechanical load signature and/or a thermal load signature.
12. The apparatus of claim 1, wherein the designated area comprises:
a first region that affects a lifetime of the structural component to a greater extent than a non-first region.
13. The apparatus of claim 12, wherein the first region further comprises:
a second region having an increased magnitude of stress cycle greater than a first threshold and/or a frequency of stress cycle variation greater than a second threshold.
14. The apparatus of claim 9, wherein the fatigue-indicating parameter comprises a remaining life of the structural component determined based on a specified operating cycle.
15. The apparatus of claim 14, wherein the fatigue calculation module is further configured to:
determining, based on the specified operating cycle and the fatigue indicating parameter, a number of times the structural component performs the specified operating cycle before a next maintenance of the structural component.
16. The apparatus of claim 15, wherein the specified operating period is a standard operating period or a non-standard operating period determined from historical operating data over the specified time period.
17. A computer storage medium having stored thereon computer-executable instructions that, when executed, perform the method of any of claims 1 to 8.
18. A computer device comprising a memory and a processor, the memory having stored thereon computer-executable instructions that, when executed, cause the processor to perform the method of any of claims 1 to 8.
19. A computer program product, tangibly stored on a computer-readable medium and comprising computer-executable instructions that, when executed, cause at least one processor to perform the method of any of claims 1 to 8.
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| WO2022087769A1 (en) * | 2020-10-26 | 2022-05-05 | 西门子燃气与电力股份有限公司 | Method and apparatus for determining low-cycle fatigue of mechanical component, and storage medium |
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| CN111721647B (en) * | 2020-06-24 | 2021-12-28 | 四川大学 | Low-cycle fatigue test data processing and internal stress evaluation method |
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