CN111256647B - Generator stator end insulation surface deformation wear detection diagnosis method - Google Patents
Generator stator end insulation surface deformation wear detection diagnosis method Download PDFInfo
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Abstract
The invention relates to a deformation and abrasion detection and diagnosis method for an insulating surface at the end part of a generator stator, which comprises the steps of firstly generating a fitting plane in the least square sense by using point cloud data of the end part; and then, the registration of point cloud data of the same position for multiple times is realized through the extraction and alignment of the characteristic points, and the 4D visual comparison and measurement of the wear value are realized by utilizing a deviation data color map. Compared with the prior art, the method effectively solves the problem that the existing detection means cannot detect the abrasion defect of the insulating surface at the early and middle stages.
Description
Technical Field
The invention relates to the field of generator insulation diagnosis, in particular to a method for detecting and diagnosing deformation and abrasion of an insulation surface at the end part of a generator stator.
Background
The generator end insulation state level directly affects the operational reliability. The detection and evaluation of the insulation wear defect at the end part of the generator are accurately and efficiently realized, and the method has important significance for improving the stability and reliability of the operation of the generator. The fault statistics result shows that the insulation defect abrasion damage of the end part of the generator is an important factor causing the insulation fault of the generator. At present, a voltage withstand test is the most main technical means for evaluating the insulation performance on site, and engineering practice proves that the effectiveness of the voltage withstand test for finding the insulation layer abrasion thinning defect is poor, only the insulation of the end part of a winding can be seriously damaged, and the insulation surface abrasion defect of early and medium degrees cannot be detected. With the development of an insulation technology, an insulation layer is thinner and thinner, the observable change of the geometric form of the insulation layer is smaller before the insulation layer is worn and thinned to fail, manual visual inspection is not feasible, a quantitative detection and evaluation technology for accurate deformation and thinning of an insulation material is urgently required to be sought, and the comprehensiveness and effectiveness of generator insulation defect diagnosis are improved. Along with the progress of space geometry high-precision sensing technology and data visualization display technology, the emerging 4D measurement technology provides possibility for solving the current troubles. The 4D measurement technology can not only realize direct and fine quantitative evaluation of the abrasion of the insulating surface of the generator, but also realize image visualization contrast evaluation of the abrasion position and the abrasion speed of the surface.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for detecting and diagnosing the deformation and abrasion of the insulating surface of the end part of the generator stator.
The purpose of the invention can be realized by the following technical scheme:
a deformation and abrasion detection and diagnosis method for an insulating surface at the end part of a generator stator comprises the steps of firstly, generating a fitting plane in the least square sense by utilizing point cloud data of the end part;
and then, the registration of point cloud data of the same position for multiple times is realized through the extraction and alignment of the characteristic points, and the 4D visual comparison and measurement of the wear value are realized by utilizing a deviation data color map.
Preferably, the method specifically comprises the following steps:
firstly, collecting early-stage feature point cloud data;
secondly, collecting later-stage feature point cloud data;
and thirdly, performing 4D detection diagnosis on the deformation and wear of the insulation surface of the generator stator by a point cloud data splicing method and an insulation wear evaluation method based on the characteristic point information.
Preferably, the collecting of the earlier-stage feature point cloud data specifically includes:
when the generator is stopped and overhauled in the early period, 5-10 points are uniformly and randomly selected at the insulation surface acquisition part of the coil bar at the end part of the stator, and refined point cloud data and related characteristic point information of the insulation part at the end part of the stator are acquired by using the measuring arm.
Preferably, the acquiring of the late-stage feature point cloud data specifically comprises:
after the generator normally works for a set time, later-stage data acquisition work is carried out, the data acquisition needs to be carried out on the insulation part acquired in the previous stage for fine measurement again, the acquisition instrument is still a measurement arm, and meanwhile the same characteristic point information as the characteristic point information in the previous stage is acquired.
Preferably, the point cloud data stitching method based on the feature point information specifically includes:
and combining the collected characteristic point information of the early-stage reference data and the later-stage comparison data to splice point clouds, wherein the point cloud splicing is carried out according to the corresponding relation of the coordinate values of the two characteristic points.
Preferably, the insulation wear evaluation method includes:
the first stage is as follows: primarily detecting abrasion;
and a second stage: defining a wear range;
and a third stage: and (5) detecting the wear in a targeted mode.
Preferably, the first stage: the wear preliminary detection specifically comprises the following steps:
selecting a plurality of points uniformly and randomly on the surface of the stator end bar in the collection area, measuring the deviation between the points and the reference point cloud, and obtaining the insulation wear value approximate distribution interval of the insulation surface according to the wear values of the points.
Preferably, the second stage: the wear range is defined specifically as:
firstly, on the basis of a preliminarily obtained wear value distribution interval, considering the randomness of sampling points, points with larger wear values may be missed, so that an interval 15 times the size of the measured wear value distribution interval is selected as an initial wear interval to be used for generating a wear deviation data graph under the interval reference;
then, properly adjusting the boundary value of the wear range interval according to the result of the deviation data color map, and regenerating the wear deviation data color map under the corresponding interval reference;
repeating the steps until different colors in the generated deviation data color map are distributed and can sufficiently reflect the insulation wear condition in a corresponding range, taking the wear interval as a final wear interval value, and taking the corresponding deviation data color map as a regional wear value measurement result.
Preferably, the initial wear interval is adjusted by appropriately adjusting a boundary value of the wear range interval according to the result of the deviation data color map: if the color type is larger than the set upper limit but is concentrated on several colors below the set numerical value, the interval is larger, and the boundary of the abrasion interval needs to be reduced; on the contrary, if the color type is smaller than the set lower limit, indicating that the interval is smaller, the interval boundary value needs to be increased until the color distribution is uniform, and the insulation wear condition in the corresponding range can be fully reflected.
Preferably, the third stage: the specific detection of the abrasion specifically comprises the following steps:
finding out the area with more serious abrasion in the finally obtained deviation data color chart, finding out the corresponding abrasion value interval according to the corresponding color distribution, and realizing the generation of the deviation data color chart of the abrasion part exceeding a set threshold value by adjusting the lower limit value of the abrasion interval, wherein the part corresponding to the color chart is the abrasion part needing important inspection, meanwhile, carrying out targeted single-point measurement on the point in the serious abrasion part, and generating a corresponding measurement report according to the result obtained by measurement.
Compared with the prior art, the invention provides a new technology for the visual quantitative evaluation of the abrasion position and the abrasion state of the end insulation of the generator, and effectively solves the problem that the existing detection means can not detect the abrasion defect of the insulation surface at the early and middle stages.
Drawings
FIG. 1 is a schematic diagram illustrating a principle of detecting a wear value at any point;
FIG. 2 is a flow chart of the detection method of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, shall fall within the scope of protection of the present invention.
The invention provides a 4D detection and diagnosis method for deformation and abrasion of an insulating surface at the end part of a generator stator based on a 3D imaging technology; according to the method, firstly, fitting planes in the least square sense are generated by using end point cloud data, then, the registration of the point cloud data of the same part for multiple times is realized by extracting and aligning characteristic points, and 4D visual comparison and measurement of wear values are realized by using a deviation data color map. The invention provides a new technology for the visual quantitative evaluation of the abrasion position and the abrasion state of the end insulation of the generator, and effectively solves the problem that the existing detection means can not detect the abrasion defect of the insulation surface at the early and middle stages.
Referring to fig. 1, the technical principle of the present invention is as follows:
first, for the current measurement object, it is considered that the insulation surface is flat in distribution in a small range interval, and it can be considered as a horizontal distribution state approximately.
Secondly, aiming at any point in the later-period comparison data, in order to calculate the wear value of the point, a fitting plane of the reference point cloud of the corresponding region needs to be calculated. The essence of the point cloud data is a three-dimensional space coordinate value, and each point corresponds to one three-dimensional space coordinate, so that a plane in the least square sense can be fitted according to k previous-stage reference point cloud data, and a reference point cloud plane Ax + By + Cz +1 is 0. It should be noted that, in order to consider both the efficiency and the accuracy of the quantitative detection algorithm, the radius of the selection range of k points in both sides of the current data is set to be 2.5 mm. If efficiency is to be improved, the sampling radius can be reduced appropriately.
Finally, any point (x) is compared with the data point cloud in the later periodi,yi,zi) And the distance between the same-phase corresponding reference point cloud plane Ax + By + Cz +1 and 0 is the insulation deformation wear value generated in the two data acquisition periods. The calculation formula is shown in the following formula, and the calculation principle is shown in fig. 2.
Referring to fig. 2, the detection method of the present invention mainly comprises three steps:
firstly, collecting early-stage feature point cloud data. The main task of the step is to detect the approximate range of deformation and abrasion of the insulating surface of the generator stator, and the basic implementation method comprises the following steps: when the generator is stopped and overhauled in the early period, 5-10 points are reasonably and uniformly selected at the insulating surface acquisition part of the coil bar at the end part of the stator at random, and refined point cloud data and related characteristic point information of the insulating part at the end part of the stator are acquired by using the measuring arm.
And secondly, collecting later-stage feature point cloud data. After the generator normally works for a period of time, later-stage data acquisition work is carried out, the data acquisition needs to be carried out on the insulation part acquired in the previous stage for fine measurement again, the acquisition instrument is still a measurement arm, and meanwhile the same characteristic point information as the characteristic point information in the previous stage is acquired.
And thirdly, performing 4D detection diagnosis on the deformation and wear of the insulation surface of the generator stator by a point cloud data splicing method and an insulation wear evaluation method based on the characteristic point information.
The point cloud data splicing method based on the characteristic point information comprises the following steps: and combining the characteristic point information of the early-stage reference data and the later-stage comparison data to splice the point clouds. Point cloud splicing is carried out according to the corresponding relation of the coordinate values of the two characteristic points
The 4D assessment method for the deformation and wear of the insulating surface of the generator stator comprises three stages of wear primary detection, wear range definition and wear targeted detection
The first stage is as follows: preliminary wear detection
In order to detect the approximate range of the deformation wear of the insulating surface, on the basis of point cloud splicing, a plurality of points are selected uniformly and randomly on the surface of a stator end bar in a collection area, the deviation between the points and a reference point cloud is measured, and the insulation wear value approximate distribution interval of the insulating surface is obtained according to the wear values of the points
And a second stage: wear range definition
In the stage, the worn section and the part with serious wear are gradually found out mainly by thinning the worn range. The method comprises the following steps:
firstly, on the basis of the preliminarily obtained wear value distribution interval, a point with a larger wear value may be missed in consideration of the randomness of the sampling point, so that an interval larger than the measured wear value distribution interval is selected as an initial wear interval and used for generating a wear deviation data map under the interval reference.
Then, the boundary value of the wear range section is properly adjusted according to the result of the deviation data color map, and the wear deviation data color map under the corresponding section standard is regenerated.
Repeating the steps until different colors in the generated deviation data color map are distributed and can sufficiently reflect the insulation wear condition in a corresponding range, taking the wear interval as a final wear interval value, and taking the corresponding deviation data color map as a regional wear value measurement result.
Third stage, wear targetted detection
The specific detection of the abrasion is carried out after the definition of the abrasion interval is completed: finding out the area with more serious abrasion in the finally obtained deviation data color chart, finding out the corresponding abrasion value interval according to the corresponding color distribution, and realizing the generation of the deviation data color chart of the abrasion part exceeding a certain threshold value by adjusting the lower limit value of the abrasion interval, wherein the part corresponding to the color chart is the abrasion part needing to be mainly checked, which represents the part which is seriously abraded in the two data acquisition and has a certain sinking condition. Meanwhile, a point in a serious abrasion part is subjected to targeted single-point measurement, and a corresponding measurement report is generated according to a result obtained by measurement.
DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION
1. Motor stator insulation surface deformation wear data acquisition
(1) Early stage reference data acquisition
(2) Late stage comparison data acquisition
And after a plurality of months, performing second data acquisition on the same part of the motor, and taking the data as comparison data to detect the abrasion condition of the insulating surface of the end part of the motor stator during the running period of the generator.
2. Point cloud data stitching
Selecting characteristic points: since the motor housing can be regarded as a steel body structure, the circular holes in the stator end core bar intervals are taken as characteristic points.
Collecting characteristic points: firstly, circular hole information is collected by a Faro measuring arm to serve as characteristic point information, and point cloud data of the insulation surface of a generator stator are collected.
Matching the characteristic points: and when the point cloud data is acquired in the later period, the feature point information which is the same as that in the earlier period is acquired at the same time, and the feature points acquired in the earlier period are ensured to be in one-to-one correspondence.
Point cloud splicing: and combining the characteristic point information of the early-stage reference data and the later-stage comparison data to splice the point clouds. And point cloud splicing is carried out according to the corresponding relation of the coordinate values of the two characteristic points.
3. Generator stator insulation surface deformation wear 4D detection
(1) Preliminary wear detection
In order to detect the approximate range of the deformation abrasion of the insulation surface, 6 points which are uniform on the surface of the stator end bar in the collection area are selected randomly on the basis of point cloud splicing, and the deviation between the points and the reference point cloud is measured. The deviation values corresponding to points 1 to 6 were-0.016 mm, -0.028mm, -0.014mm, -0.013mm, -0.007mm and-0.015 mm, respectively. From the above results, it is understood that the maximum abrasion value of 6 sampling points is-0.028 mm, which means that the approximate distribution range of the deformation abrasion can be obtained.
(2) Wear range definition
Considering that the abrasion values of 6 sampling points are all within-0.034 mm and the sampling points have certain randomness and points with larger abrasion values are probably missed, in order to fully reflect the insulation abrasion condition of the whole end part, 0-0.5 mm larger than the measured abrasion distribution interval is selected as an initial abrasion interval, and a corresponding deviation data color chart is generated. The position of the wear occurrence region can be seen, and meanwhile, according to different wear colors, the wear value is almost completely positioned in the upper color interval, which means that the wear value is far smaller than the maximum value of the set interval. Therefore, the wear detection range is further reduced to 0-0.25 mm, and a deviation color chart is generated. From the results it can be seen that the abrasion value is still less than the interval maximum and the colour lies substantially within-0.1 mm. Therefore, the detection range is further narrowed to 0-0.1 mm according to the result, and a deviation data color chart is generated. From the display results, it is found that the colors representing the different deviations within the range are distributed, and the wear distribution in the entire wear area can be sufficiently reflected, so that the detection range is set as the final wear value detection section.
(3) Wear-targeting detection
In order to verify the accuracy of the deviation data color image result, the detection result is firstly compared with the measurement result of the sampling point, and the two measurement results can be found to be consistent, the color interval is correct, and the deviation data color image result is reliable.
In order to perform targeted detection on the serious wear area, the area with serious wear can be found out according to the color distribution position in the finally obtained deviation data color map, the corresponding wear value interval is found to be-0.022 mm-0.100 mm, and the generation of the deviation data color map of the wear part exceeding a certain threshold value can be realized by adjusting the lower limit value of the wear interval to be-0.022 mm. The part corresponding to the color map is a wear part needing to be mainly checked, and represents a part which is seriously worn in two data acquisition processes, and a certain sinking condition exists.
While the invention has been described with reference to specific embodiments, the invention is not limited thereto, and various equivalent modifications and substitutions can be easily made by those skilled in the art within the technical scope of the invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (6)
1. A detection and diagnosis method for deformation and abrasion of an insulating surface at the end part of a generator stator is characterized by firstly generating a fitting plane in the least square sense by using point cloud data of the end part;
then, the registration of point cloud data of the same position for multiple times is realized through the extraction and alignment of the characteristic points, and 4D visual comparison and measurement of the wear value are realized by utilizing a deviation data color map;
the method specifically comprises the following steps:
firstly, collecting early-stage feature point cloud data;
secondly, collecting later-stage feature point cloud data;
thirdly, performing 4D detection diagnosis on the deformation and wear of the insulation surface of the generator stator by a point cloud data splicing method and an insulation wear evaluation method based on the characteristic point information;
the acquisition early-stage feature point cloud data specifically comprises the following steps:
when the generator is stopped and overhauled in the early period, 5-10 points are uniformly and randomly selected at the collection part of the insulation surface of the coil bar at the end part of the stator, and refined point cloud data and related characteristic point information of the insulation part at the end part of the stator are collected by using a measuring arm;
the insulation wear evaluation method comprises the following steps:
the first stage is as follows: primarily detecting abrasion;
and a second stage: defining a wear range;
and a third stage: targeted detection of wear;
the second stage is as follows: the wear range is defined specifically as:
firstly, on the basis of a preliminarily obtained wear value distribution interval, considering the randomness of sampling points, points with larger wear values may be missed, so that an interval 15 times the size of the measured wear value distribution interval is selected as an initial wear interval to be used for generating a wear deviation data graph under the interval reference;
then, properly adjusting the boundary value of the wear range interval according to the result of the deviation data color map, and regenerating the wear deviation data color map under the corresponding interval reference;
repeating the steps until different colors in the generated deviation data color map are distributed and can sufficiently reflect the insulation wear condition in a corresponding range, taking the wear interval as a final wear interval value, and taking the corresponding deviation data color map as a regional wear value measurement result.
2. The method for detecting and diagnosing the deformation and abrasion of the insulating surface of the end part of the generator stator according to claim 1, wherein the collecting of the later-stage feature point cloud data specifically comprises:
after the generator normally works for a set time, later-stage data acquisition work is carried out, the data acquisition needs to be carried out on the insulation part acquired in the previous stage for fine measurement again, the acquisition instrument is still a measurement arm, and meanwhile the same characteristic point information as the characteristic point information in the previous stage is acquired.
3. The method for detecting and diagnosing the deformation and abrasion of the insulating surface of the end part of the generator stator according to claim 1, wherein the method for splicing the point cloud data based on the characteristic point information specifically comprises the following steps:
and combining the collected characteristic point information of the early-stage reference data and the later-stage comparison data to splice point clouds, wherein the point cloud splicing is carried out according to the corresponding relation of the coordinate values of the two characteristic points.
4. The method for detecting and diagnosing the deformation and abrasion of the insulating surface of the end part of the generator stator as claimed in claim 1, wherein the first stage comprises the following steps: the wear preliminary detection specifically comprises the following steps:
selecting a plurality of points uniformly and randomly on the surface of the stator end bar in the collection area, measuring the deviation between the points and the reference point cloud, and obtaining the insulation wear value approximate distribution interval of the insulation surface according to the wear values of the points.
5. The method for detecting and diagnosing the deformed wear of the insulating surface of the end part of the generator stator as claimed in claim 4, wherein the initial wear interval is obtained by properly adjusting the boundary value of the wear range interval according to the result of the deviation data color map: if the color type is larger than the set upper limit but is concentrated on several colors below the set numerical value, the interval is larger, and the boundary of the abrasion interval needs to be reduced; on the contrary, if the color type is smaller than the set lower limit, indicating that the interval is smaller, the interval boundary value needs to be increased until the color distribution is uniform, and the insulation wear condition in the corresponding range can be fully reflected.
6. The method for detecting and diagnosing the deformation and abrasion of the insulating surface of the end part of the stator of the generator as claimed in claim 1, wherein the third stage: the specific detection of the abrasion specifically comprises the following steps:
finding out the area with more serious abrasion in the finally obtained deviation data color chart, finding out the corresponding abrasion value interval according to the corresponding color distribution, and realizing the generation of the deviation data color chart of the abrasion part exceeding a set threshold value by adjusting the lower limit value of the abrasion interval, wherein the part corresponding to the color chart is the abrasion part needing important inspection, meanwhile, carrying out targeted single-point measurement on the point in the serious abrasion part, and generating a corresponding measurement report according to the result obtained by measurement.
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| CN101358843B (en) * | 2008-08-22 | 2012-08-29 | 华东电力试验研究院有限公司 | Wall thickness detecting system for high-temperature inner barrel |
| CN102853799A (en) * | 2012-08-27 | 2013-01-02 | 长沙学院 | Detection device of abraded shape and mass loss and detection method thereof |
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| EP2165915A3 (en) * | 2008-09-23 | 2011-04-13 | VolkerRail Nederland BV | Monitoring a turnout of a railway or tramway line |
| CN104422422A (en) * | 2013-08-30 | 2015-03-18 | 鸿富锦精密工业（深圳）有限公司 | Product profile deformation analysis system and method |
| CN105526882A (en) * | 2015-12-28 | 2016-04-27 | 西南交通大学 | Turnout wear detection system and detection method based on structured light measurement |
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