CN111749856A - Air gap detection method, wind generating set and air gap monitoring system - Google Patents
Air gap detection method, wind generating set and air gap monitoring system Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
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Abstract
The invention relates to an air gap detection method, a wind generating set and an air gap monitoring system, wherein the air gap detection method is used for a generator and comprises the following steps: obtaining an initial air gap detection value according to an air gap sensor, wherein the air gap sensor is arranged between a stator and a rotor of the generator and connected to a stator iron core so as to detect an air gap between the stator and the rotor; obtaining an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between the preset air gap detection value and the sensing error caused by the rotor coating; and compensating the initial air gap detection value by using the error compensation value to obtain a final air gap detection value between the stator and the rotor. The invention can compensate the air gap value between the rotor and the stator of the generator fed back by the sensor, ensures the authenticity of the air gap value of the generator, is beneficial to the detection of the health level of the generator and can provide a basis for cost reduction development of the generator.
Description
Technical Field
The invention relates to the technical field of wind power, in particular to an air gap detection method, a wind generating set and an air gap monitoring system.
Background
In a generator, the size of the air gap between the rotor and the stator determines the size of the magnetic flux, and if the air gap is not uniform, the induced electromotive force and current generated in the rotor winding are reduced, so the air gap is an important parameter index in the generator. The uniformity of the air gap will directly affect the stability of the generator. Therefore, in order to reduce the cost of the generator and further improve the economic performance of the generator, the air gap amount of the generator is usually designed and considered as a key factor.
The generator is used as an important component of the wind generating set, an air gap between a rotor and a stator of the generator needs to be monitored through a sensor, and the performance of the generator is fed back through the air gap so as to ensure the generating benefit of the wind generating set. And in order to guarantee the security and the life of generator, can carry out the injecting glue and enamel is anticorrosive on the rotor magnetic pole of generator usually, consequently can form rotor coatings such as glue film, magnetic paint layer on the rotor magnetic pole, the existence of rotor coating makes the air gap value of sensor feedback inaccurate, has the error with the true value of air gap, is unfavorable for monitoring the health level of generator, and simultaneously, the reduction of generator air gap authenticity is unfavorable for providing the basis for the development that falls of generator.
Disclosure of Invention
The embodiment of the invention provides an air gap detection method, a wind generating set and an air gap monitoring system, which can compensate an air gap value between a generator rotor and a generator stator fed back by a sensor, ensure the authenticity of the air gap value of the generator, are beneficial to the detection of the health level of the generator and can provide a basis for cost reduction development of the generator.
In one aspect, an air gap detection method is provided according to an embodiment of the present invention, and is used for a generator, and the method includes:
obtaining an initial air gap detection value according to an air gap sensor, wherein the air gap sensor is arranged between a stator and a rotor of the generator, and the air gap sensor is arranged on the surface of a stator iron core facing the rotor so as to detect an air gap between the stator and the rotor;
obtaining an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between the preset air gap detection value and the sensing error caused by the rotor coating;
and compensating the initial air gap detection value by using the error compensation value to obtain a final air gap detection value between the stator and the rotor.
According to one aspect of an embodiment of the present invention, the final air gap detection value is equal to a sum of the initial air gap detection value and a corresponding error compensation value.
According to an aspect of an embodiment of the invention, the method further comprises: and obtaining a detection value of the air gap between the stator and the rotor coating according to the thickness of the rotor coating, the initial air gap detection value and the error compensation value.
According to an aspect of the embodiment of the present invention, the step of obtaining the detection value of the air gap between the stator and the rotor coating according to the thickness of the rotor coating, the detection value of the initial air gap and the error compensation value comprises: calculating the sum of the error compensation value and the initial air gap detection value; the difference between the sum and the thickness of the rotor coating is taken as the measured value of the air gap between the stator and rotor coating.
According to an aspect of the embodiment of the present invention, the correspondence between the preset air gap detection value and the sensing error caused by the rotor coating is determined by the first correspondence and the second correspondence; the first corresponding relation is the corresponding relation between an air gap detection value and a preset air gap set under the condition that a rotor cladding exists on the rotor; the second corresponding relation is the corresponding relation between the air gap detection value and a preset air gap set under the condition that the rotor is not coated with the rotor.
According to an aspect of the embodiment of the present invention, the step of obtaining the initial air gap detection value according to the air gap sensor includes: obtaining a sampling wave of the air gap sensor; carrying out waveform analysis on the sampling wave to obtain a value of an electric signal corresponding to the sampling wave; and obtaining an initial air gap detection value according to the calibration relation between the preset value of the electric signal and the air gap detection value.
According to an aspect of an embodiment of the invention, the method further comprises: and determining the eccentricity of the rotor relative to the stator according to the final air gap detection values fed back by the two or more air gap sensors respectively, wherein the two or more air gap sensors are arranged at intervals in the axial direction of the stator core.
In another aspect, an embodiment of the present invention provides a wind turbine generator system, including: the generator comprises a rotor and a stator which are in running fit, the stator comprises a stator core and a stator coil which are connected with each other, and the rotor comprises a rotor magnetic pole; an air gap sensor disposed on a surface of the stator core facing the rotor to detect an air gap between the stator and the rotor; and the main controller obtains an initial air gap detection value according to the air gap between the stator and the rotor detected by the air gap sensor, obtains an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between the preset air gap detection value and the sensing error caused by the rotor coating, and compensates the initial air gap detection value by using the error compensation value to obtain a final air gap detection value between the stator and the rotor.
According to an aspect of the embodiments of the present invention, the air gap sensor includes a plurality of first plate-type capacitance sensors disposed at intervals in a circumferential direction of the stator core and at least one second plate-type capacitance sensor disposed at intervals in an axial direction of the stator core from one of the first plate-type capacitance sensors, the first plate-type capacitance sensor and the second plate-type capacitance sensor both facing the rotor magnetic pole; the plurality of first plate-type capacitive sensors are arranged close to the end parts of the stator core in the axial direction, and lead wires of the first plate-type capacitive sensors penetrate through gaps of the stator coils; and/or the second plate-type capacitance sensor is positioned at the middle part or the position close to the middle part of the stator core in the axial direction, and the lead of the second plate-type capacitance sensor passes through the ventilation hole of the stator core and is intersected with the lead of the first plate-type capacitance sensor.
According to an aspect of the embodiment of the invention, the stator further comprises a ventilation cover plate and a filter box, the wind generating set further comprises adapters in one-to-one correspondence with the first plate-type capacitive sensor and the second plate-type capacitive sensor, and the adapters and the stator are jointly connected to a ground wire; the adapter is attached to the cartridge or alternatively, the adapter is attached to the vent flap of the stator by a snap fit.
According to an aspect of an embodiment of the invention, the wind power plant is a horizontal axis wind turbine.
According to one aspect of the embodiment of the invention, the rotor is arranged outside the stator, one ends of the rotor and the stator in the axial direction are connected through a rotary bearing, the plurality of first plate-type capacitance sensors are positioned at the end part of the stator iron core far away from the rotary bearing, and the rotor magnetic poles comprise permanent magnets.
In another aspect, an air gap monitoring system is provided according to an embodiment of the present invention, including: the wind generating set, the centralized controller and the cloud server are arranged; the main controller of the wind generating set sends the final air gap detection value to the centralized controller; the centralized controller stores and uploads the final air gap detection value; and the cloud server is used for receiving and storing the final air gap detection value.
According to the air gap detection method, the wind generating set and the air gap monitoring system provided by the embodiment of the invention, the air gap detection method can obtain an initial air gap detection value through the air gap sensor, obtain an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between the preset air gap detection value and a sensing error caused by a rotor coating, and compensate the initial air gap detection value through the error compensation value, so that the obtained final air gap detection value can truly feed back the air gap of the generator, the detection of the health level of the generator is facilitated, and a basis can be provided for cost reduction development of the generator.
Drawings
Features, advantages and technical effects of exemplary embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a schematic structural view of a wind turbine generator system according to an embodiment of the present invention;
FIG. 2 is a schematic view of a partial structure of a generator according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of an embodiment of the present invention characterizing the air gaps of a generator;
FIG. 4 is a schematic flow chart diagram of a method for air gap detection in accordance with one embodiment of the present invention;
FIG. 5 is a schematic flow chart of a method for detecting an air gap according to another embodiment of the present invention;
FIG. 6 is a schematic diagram of a hardware system for obtaining an initial air gap measurement in accordance with an embodiment of the present invention;
FIG. 7 is a graph showing a calibration relationship between values of a predetermined electric signal and a detected value of an air gap;
FIG. 8 is a graph comparing rotor coating effect air gap variation in an air gap sensing method according to an embodiment of the present invention;
FIG. 9 is a graph of the relationship between the rotor coating and the predetermined air gap sensing value when the air gap sensing method of the embodiment of the present invention employs current output;
FIG. 10 is a graph of the relationship between the rotor coating and the predetermined air gap sensing value when the voltage output is applied to the air gap sensing method according to the embodiment of the present invention;
FIG. 11 is a simplified connection diagram of a rotor, stator and air gap sensor in accordance with an embodiment of the present invention;
FIG. 12 is a schematic view of an air gap sensor arrangement on a stator according to an embodiment of the present invention;
FIG. 13 is a schematic diagram of the structure of the skewness analysis of one embodiment of the present invention;
FIG. 14 is a partial schematic view of a generator according to another embodiment of the present invention;
FIG. 15 is a schematic view of the trend of air gaps of four first plate-type capacitive sensors according to an embodiment of the present invention;
FIG. 16 is a schematic view of an installation of an adapter according to an embodiment of the present invention;
FIG. 17 is a schematic view of the mounting of the front-end of an embodiment of the invention;
FIG. 18 is a connection routing diagram of the front end;
FIG. 19 is a schematic structural diagram of an air gap detection system according to an embodiment of the present invention.
Wherein:
100-a wind generating set; x-axial direction; y-circumferential direction;
10-a generator; 110-a rotor; 111-rotor poles; 112-rotor cladding; 120-a stator; 121-a stator core; 121 a-drum end; 122-stator coils; 123-filter cartridge; 124-cover plate; 130-bearing constraint;
20-an air gap sensor; 210-a first plate capacitance sensor; 210 a-a lead; 220-a second plate capacitance sensor; 220 a-lead;
30-a main controller; 40-an adapter; 50-a pre-positioner; 60-a cabinet; 70-a tower drum; 80-a nacelle; 90-impeller; 91-a hub; 92-a blade;
200-a centralized controller;
300-cloud server.
In the drawings, like parts are provided with like reference numerals. The figures are not drawn to scale.
Detailed Description
Features and exemplary embodiments of various aspects of the present invention will be described in detail below. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. The following description of the embodiments is merely intended to provide a better understanding of the present invention by illustrating examples of the present invention. In the drawings and the following description, at least some well-known structures and techniques have not been shown in detail in order to avoid unnecessarily obscuring the present invention; also, the dimensions of some of the structures may be exaggerated for clarity. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
The following description is given by way of directional words, which are directions shown in the drawings, and does not limit the specific structure of the air gap detection method, the wind turbine generator system and the air gap monitoring system according to the present invention. In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "mounted" and "connected" are to be interpreted broadly, e.g., as either a fixed connection, a removable connection, or an integral connection; can be directly connected or indirectly connected. The specific meaning of the above terms in the present invention can be understood as appropriate to those of ordinary skill in the art.
For better understanding of the present invention, the following describes in detail an air gap detection method, a wind turbine generator system and an air gap monitoring system according to embodiments of the present invention with reference to fig. 1 to 19.
Referring to fig. 1 to 3 together, fig. 1 shows a schematic structural diagram of a wind generating set according to an embodiment of the present invention, fig. 2 shows a schematic partial structural diagram of a generator according to an embodiment of the present invention, and fig. 3 shows a schematic diagram representing air gaps of the generator. The embodiment of the invention provides a wind generating set 100, which comprises a tower 70, a nacelle 80, a generator 10, an impeller 90, an air gap sensor 20 and a main controller 30, wherein the nacelle 80 is supported on the tower 70, and the generator 10 may be disposed outside the nacelle 80, but may also be disposed inside the nacelle 80 in some examples. In one example, the wind park 100 is a horizontal axis wind generator, in particular, the wind park 100 is a permanent magnet direct drive wind generator.
The generator 10 comprises a rotor 110 and a stator 120 which are rotationally matched, the rotor 110 is arranged outside the stator 120, the stator 120 comprises a stator core 121 and a stator coil 122 fixedly arranged on the stator core 121, the rotor 110 comprises a rotor magnetic pole 111, the rotor magnetic pole 111 and the stator core 121 are arranged opposite to each other in the radial direction of the stator 120, a rotor coating 112 is arranged on one side of the rotor magnetic pole 111 facing the stator 120, the rotor coating 112 comprises a glue layer and/or an enamel layer, and the air gap sensor 20 is arranged between the rotor magnetic pole 111 and the stator core 121. In one example, the air gap sensor 20 is disposed on a surface of the stator core 121 facing the rotor 110. The rotor poles 111 include permanent magnets, for example, magnetic steel.
Optionally, in order to better realize the relative rotation between the rotor 110 and the stator 120, and further ensure the power generation efficiency of the generator 10, one end of the rotor 110 and one end of the stator 120 in the axial direction X of the stator core 121 are connected through a slewing bearing.
The impeller 90 includes a hub 91 and a plurality of blades 92, the impeller 90 is connected to the rotor 110 of the generator 10 through the hub 91, the impeller 90 rotates under the action of wind energy, and then the rotor magnetic poles 111 of the generator 10 are driven to rotate relative to the stator 120, so as to cut the magnetic induction lines, and the generator 10 generates electricity. In one example, the inner diameter of the rotor 110 is about 4 to 5m, the air gap between the stator 120 and the rotor 110 is about 4 to 7mm, for example, and the thickness of the rotor coating 112 is about 1mm, the impeller 90 rotates to drive the rotor 110 to rotate, the minimum value of the air gap can reach about 3mm during the rotation, and the measurement error caused by the thickness of the rotor coating 112 will seriously affect the measurement accuracy of the air gap.
The air gap sensor 20 is configured to detect an air gap between the stator 120 and the rotor 110 and feed back an initial detected air gap value D0 between the stator 120 and the rotor 110, and the air gap sensor 20 may be a capacitive air gap sensor 20, and may be a flat plate type capacitive sensor.
A main controller 30 may be disposed on tower 70 and/or nacelle 80, and the main controller 30 may be configured to receive an initial detected air gap value D0 fed back by air gap sensor 20 and compensate the initial detected air gap value D0 with the influence of rotor coating 112 on rotor pole 111 to obtain a final detected air gap value D1 between stator 120 and rotor 110. The authenticity of the air gap value of the generator 10 is guaranteed, the detection of the health level of the generator 10 is facilitated, and meanwhile, a basis can be provided for cost reduction development of the generator 10.
Referring to fig. 4, fig. 4 is a flow chart illustrating an air gap detecting method according to an embodiment of the invention. In order to enable the main controller 30 to accurately obtain the final air gap detection value D1 of the generator 10, an embodiment of the present invention further provides an air gap detection method for the generator 10, which is used for detecting the final air gap detection value D1 between the rotor 110 and the stator 120 of the generator 10, and the main controller 30 of the wind turbine generator system 100 can execute the method, as shown in fig. 4, the air gap detection method includes:
s100, an initial air gap detection value D0 is obtained according to the air gap sensor 20. The air gap sensor 20 is disposed between the stator 120 and the rotor 110 of the generator 10 to detect an air gap between the stator 120 and the rotor 110.
And S200, obtaining an error compensation value corresponding to the initial air gap detection value D0 according to the corresponding relation between the preset air gap detection value and the sensing error caused by the rotor coating 112.
S300, the initial air gap detection value D0 is compensated by the error compensation value, and a final air gap detection value D1 between the stator 120 and the rotor 110 is obtained.
The air gap detection method provided by the embodiment of the invention can compensate the initial air gap detection value D0 between the rotor 110 and the stator 120 of the generator 10 fed back by the air gap sensor 20, ensure the authenticity of the air gap value of the generator 10, is beneficial to detecting the health level of the generator 10 and can provide a basis for cost reduction development of the generator 10.
As an alternative embodiment, in step S300, the final air gap detection value D1 is equal to the sum of the initial air gap detection value D0 and the corresponding error compensation value.
Referring to fig. 5 to 7 together, fig. 5 is a schematic flow chart of an air gap detection method according to another embodiment of the present invention, fig. 6 is a schematic diagram of a hardware system for obtaining an initial air gap detection value D0 according to an embodiment of the present invention, and fig. 7 is a diagram illustrating a calibration relationship between a preset value of an electrical signal and an air gap detection value. In some alternative examples, the step of obtaining the initial air gap detection value D0 according to the air gap sensor 20 includes:
and S101, obtaining a sampling wave of the air gap sensor 20.
And S102, carrying out waveform analysis on the sampling wave to obtain the value of the electric signal corresponding to the sampling wave.
S103, obtaining an initial air gap detection value D0 according to a calibration relation between a preset electric signal value and the air gap detection value.
As shown in fig. 6, the air gap sensor 20 may be referred to as AGS, the adapter 40 may be referred to as AGA, and the preamble 50 may be referred to as AGC. In step S101, the air gap between the rotor 110 and the stator 120 may be converted into capacitance by the air gap sensor 20, then the air gap sensor 20 may be excited by the adapter 40 and the capacitance collected by the air gap sensor 20 may be transmitted to the pre-stage 50 in the form of voltage, and then the frequency greater than 1000Hz is filtered by the low frequency modulation and low pass filtering of the detector circuit, and then the signal amplification is performed, and the voltage signal is converted into a current signal, thereby realizing the output form of two waveforms of the current sampling wave and the voltage sampling wave.
In step S102, the current sampling wave and/or the voltage sampling wave may be analyzed and an average value or a minimum value of the current may be calculated, and/or an average value or a minimum value of the voltage may be calculated and correspondingly output to the collecting unit.
In step S103, the main controller 30 of the wind turbine generator system 100 may collect the current signal or the voltage signal transmitted by the front-end 50 by using the EL 3124. And converting the current signal or the voltage signal into an air gap detection value according to the calibration relation chart shown in fig. 7, namely the air gap detection value is the initial air gap detection value D0.
As an alternative embodiment, in step 200, the correspondence between the preset air gap detection value and the sensing error caused by the rotor coating 112 of the rotor 110 is determined according to the first correspondence and the second correspondence. The first corresponding relationship is a corresponding relationship between the detected air gap value and a preset air gap set under the condition that the rotor 110 has the rotor coating 112. The second correspondence relationship is a correspondence relationship between the detected air gap value and a preset set of air gaps in the case where the rotor 110 has no rotor coating 112.
Referring to fig. 8 to 10 together, fig. 8 shows a comparison graph of the rotor coating 112 influencing the air gap variation in the air gap detection method according to the embodiment of the present invention, fig. 9 shows a relationship graph of the rotor coating 112 and a preset air gap detection value when the air gap detection method according to the embodiment of the present invention adopts current output, and fig. 10 shows a relationship graph of the rotor coating 112 and the preset air gap detection value when the air gap detection method according to the embodiment of the present invention adopts voltage output.
Specifically, in order to better obtain the first corresponding relationship and the second corresponding relationship, a part of the rotor magnetic pole 111 and the rotor coating 112 corresponding to the part may be cut on a prototype of the generator 10, for convenience of description, the cut part of the rotor magnetic pole 111 is referred to as a sample magnetic steel, and the corresponding cut part of the rotor coating 112 is referred to as a sample rotor coating.
As shown in fig. 8, the abscissa of fig. 8 represents the sampled point values, and the ordinate represents the air gap, also called air gap detection value, in millimeters. Fixing the sample magnetic steel at a preset position, limiting the surface for arranging the rotor coating 112 as a reference surface, selecting a sample air gap sensor of the same type as the prototype of the generator 10 to be away from the reference surface of the sample magnetic steel by a preset distance, and measuring for multiple times (for example, more than ten thousand times) at the same distance, so that the sample air gap sensor feeds back multiple air gap detection values at the same distance from the reference surface. Then gradually increasing the distance between the sample air gap sensor and the reference surface according to a predetermined sequence, and measuring a plurality of air gap detection values detected by the sample air gap sensor under the condition that the sample magnetic steel is not provided with the rotor coating 112, so as to form a second corresponding relation shown in the area A on the left side of the vertical line of FIG. 8 without the rotor coating 112, that is: the correspondence between the detected air gap values and the preset set of air gaps in the absence of the rotor coating 112 for the rotor 110.
In one example, the distance between the sample air gap sensor and the reference plane is gradually increased according to the predetermined sequence, and specifically, the distance between the sample air gap sensor and the reference plane is initially 3.5mm, and then is increased to 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm, 7mm, 7.5mm, 8mm, and 8.5mm according to the predetermined sequence.
When the distance between the sample air gap sensor and the reference surface is increased to a preset value, the sample rotor coating can be instantly adhered to the reference surface of the sample magnetic steel, then the distance between the sample air gap sensor and the reference surface is gradually reduced within the corresponding time, and multiple air gap detection values are fed back under the same distance, so that a function curve of a rotor coating 112 area on a right side B area of a vertical line of fig. 8 is formed to be a first corresponding relation, namely, under the condition that the rotor coating 112 exists on the rotor 110, the corresponding relation between the air gap detection values and a preset air gap set is formed.
Similarly, the distance between the air gap sensor 20 and the reference plane may be decreased gradually from large to small according to the above-mentioned time sequence to 8.5mm, and then decreased to 8mm, 7.5mm, 7mm, 6.5mm, 6mm, 5.5mm, 5mm, 4.5mm, 4mm, and 3.5mm according to a predetermined time sequence.
As shown in fig. 9, the error compensation value is obtained by obtaining a difference between the air gap detection values fed back by the sample air gap sensor under the same distance condition between the sample air gap sensor and the reference surface, the multiple error compensation values and discrete points corresponding to the air gap initial value can be obtained by the multiple error compensation values, and the air gap initial value and the error compensation value are approximately in a linear relationship by the multiple discrete points, so as to obtain a functional relationship between the air gap initial value and the error compensation value.
Fig. 9 is a diagram obtained by converting the capacitance detected by the sample air gap sensor 20 into a current through a calibration relationship with the capacitance detected by the sample air gap sensor, and then performing time domain analysis and plotting on the air gap detection value obtained correspondingly.
Referring to fig. 10, in some other examples, the capacitance detected by the sample air gap sensor 20 may be converted into a voltage through a calibration relationship, and then the air gap detection value is plotted, and the measurement method is the same as above.
As can be seen from fig. 9 and 10, the results obtained from the two are approximately the same, and the influence of the rotor coating 112 on the air gap between the rotor 110 and the stator 120 can be mutually verified.
When the initial air gap detection value D0 is obtained by the air gap sensor 20, the error compensation value corresponding to the initial air gap detection value D0 is obtained by a functional relationship between the initial air gap value and the error compensation value, and the final air gap detection value between the rotor and the stator is obtained by summing the error compensation value and the initial air gap detection value D0.
According to the air gap detection method provided by the embodiment of the invention, the corresponding relation between the preset air gap detection value and the sensing error caused by the rotor coating 112 of the rotor 110 is defined, the first corresponding relation and the second corresponding relation are determined, and the obtaining mode of the first corresponding relation and the second corresponding relation is defined, so that the error compensation value can be obtained more easily, and the accuracy of the error compensation value can be ensured.
As an optional implementation, the air gap detection method further includes obtaining a detected value D2 of the air gap between the stator 120 and the rotor cover 112 of the rotor 110 according to the thickness of the rotor cover 112 of the rotor 110, the detected value D0 of the initial air gap, and the error compensation value. By obtaining the air gap detection value D2 between the stator 120 and the rotor cladding 112, the information of the main bearing of the direct drive unit can be laterally known, predictive maintenance is achieved, and the unit availability is improved.
In some alternative examples, the step of obtaining the measured value of the air gap between the stator 120 and the rotor cover 112 based on the thickness of the rotor cover 112, the measured value of the initial air gap D0, and the error compensation value includes: the sum of the error compensation value and the initial air gap detection value D0, which may be considered the final air gap detection value D1, is calculated as the difference between the sum and the thickness of the rotor coating 112 as the air gap detection value D2 between the stator 120 and the rotor coating 112 of the rotor 110, which may also be referred to as the mechanical air gap.
The air gap detection value between the stator 120 and the rotor 110 and the rotor coating 112 obtained in the mode is high in accuracy and more accurate, a basis can be further provided for model machine development, the health level of the generator 10 is monitored, errors caused by air gap measurement of the air gap sensor 20 are reduced through absolute air gap measurement, the authenticity of the air gap of the generator 10 can be reflected, and effective data support and a solid foundation basis are laid for reducing the gap and cost of megawatt direct-drive models.
To sum up, according to the air gap detection method provided by the embodiment of the present invention, the initial air gap detection value D0 can be obtained by the air gap sensor 20, the error compensation value corresponding to the initial air gap detection value D0 is obtained according to the corresponding relationship between the preset air gap detection value and the sensing error caused by the rotor coating 112, and the initial air gap detection value D0 is compensated by the error compensation value, so that the obtained final air gap detection value D1 can truly feed back the air gap of the generator 10, which is beneficial to the detection of the health level of the generator 10 and can provide a basis for cost reduction and development of the generator 10, and meanwhile, an instructive suggestion can be provided for a unit control strategy.
Referring to fig. 11 to 13, fig. 11 is a schematic view illustrating connection of the rotor 110, the stator 120 and the air gap sensor 20 according to the embodiment of the invention. Fig. 12 shows a schematic layout of the air gap sensor 20 on the stator 120 according to the embodiment of the present invention. FIG. 13 shows a schematic diagram of the skewness analysis of one embodiment of the present invention.
As shown in fig. 11, since the rotor 110 and the stator 120 are rotatably connected by the slewing bearing at one end of the stator core 121 in the axial direction X, a bearing constraint 130 is formed only at the position of the slewing bearing, and the other ends of the rotor 110 and the stator 120 away from the slewing bearing in the axial direction X are in a cantilever state, and in some examples, the rotor magnetic poles are relatively easy to vibrate and deform because the rotor magnetic poles are permanent magnets. Therefore, in order to better adapt to the generator with such a structure and enable more accurate detection of the final air gap detection value D1 between the rotor 110 and the stator 120 of the generator 10, the air gap sensor 20 optionally includes a plurality of first plate-type capacitance sensors 210 arranged at intervals along the circumferential direction Y of the stator core 121 on the stator core 121, and at least one second plate-type capacitance sensor 220 arranged at intervals with one of the first plate-type capacitance sensors 210 in the axial direction X of the stator core 121, and each of the first plate-type capacitance sensors 210 and the second plate-type capacitance sensor 220 faces the rotor magnetic pole 111.
Referring to fig. 14, fig. 14 is a partial schematic structural diagram of a generator 10 according to another embodiment of the present invention. As an alternative embodiment, the plurality of first plate-type capacitive sensors 210 are disposed near an end of the stator core 121, which is an end of the stator core 121 facing the tower 70, that is, an end away from the slewing bearing, and for convenience of description, an end of the stator core 121 facing the tower 70 is referred to as a tower end 121 a. Optionally, the distance between the first plate-type capacitive sensors 210 and the tower end 121a is any value between 15mm and 25mm, including both ends of 15mm and 25mm, further optionally 18mm to 23mm, and preferably 20 mm. The distance is determined by the 90 ° routing of the long flexible cable at the root of each first plate air gap sensor 20, and the lead 210a of the first plate capacitive sensor 210 is passed through the gap of the stator coil 122.
As described above, the end of the rotor 110 and the end of the stator 120 far from the slewing bearing are in a cantilever state, and the vibration amplitude is large, so that the fluctuation range of the air gap is large, the end where the plurality of first plate-type capacitance sensors 210 are close to the stator core 121 is limited to the end far from the slewing bearing, and the position where the fluctuation range of the air gap between the rotor 110 and the stator 120 is large can be monitored.
For example, as shown in fig. 12 to 14, in some alternative examples, the number of the first plate-type capacitive sensors 210 may be four, four first plate-type capacitive sensors 210 are uniformly arranged along the circumferential direction Y of the stator core 121, and the angles between two adjacent first plate-type capacitive sensors 210 are equal. Alternatively, the four first plate type capacitance sensors 210 may be disposed in the 3 o 'clock, 6 o' clock, 9 o 'clock, and 12 o' clock directions of the stator core 121, respectively. The number of the second plate-type capacitance sensors 220 may be selected to be one, and one second plate-type capacitance sensor 220 is provided at a distance from the first plate-type capacitance sensor 210 located at 12 o' clock in the axial direction X of the stator core 121.
Referring to fig. 11 to 15, fig. 15 is a schematic diagram illustrating a trend of air gaps of four first plate-type capacitive sensors 210 according to an embodiment of the invention. The abscissa in fig. 15 represents the number of sampling points, and the ordinate represents the value of the air gap variation. Fig. 15 shows four corresponding air gap variation curves of the four first plate-type capacitive sensors 210, namely, a curve 210a, a curve 210b, a curve 210c, and a curve 210d, where the four air gap variation curves can represent an air gap variation diagram of each first plate-type capacitive sensor 210 when the rotor 110 rotates relative to the stator 120 for one turn, and as can be verified again by the air gap variation diagram, the rotor 110 vibrates greatly at the cantilever end position thereof relative to the stator 120, and the air gap variation ranges of the two are wide.
Because the four first plate-type capacitance sensors 210 are located at the position where the vibration amplitude of the rotor is large, the position where the fluctuation range of the air gap between the rotor 110 and the stator 120 is large can be monitored by analyzing the air gaps fed back by the four first plate-type capacitance sensors 210, the air gap values between the rotor 110 and the stator 120 which are respectively detected are respectively fed back by using the plurality of first plate-type capacitance sensors 210, the running state of the generator 10 is better monitored, the structure of the generator 10 is optimized, the position where the variation range of the air gap between the rotor 110 and the stator 120 is large can meet the requirement of air gap variation, the normal running of the generator 10 can be ensured, and the safe running monitoring, the structure optimization design and the cost reduction requirement of the generator 10 are more facilitated.
With continued reference to fig. 11 to 15, alternatively, the second plate-type capacitance sensor 220 is located at or near the middle of the stator core 121 in the axial direction X, and the leads 220a of the second plate-type capacitance sensor 220 pass through the ventilation holes of the stator core 121 and intersect the leads 210a of the first plate-type capacitance sensor 210. The routing form of the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220 can ensure the reliability of the electrical connection, and can avoid the influence on the rotation between the rotor 110 and the stator 120 of the generator 10.
Since the air gap sensor 20 includes at least one second plate-type capacitive sensor 220 spaced apart from one first plate-type capacitive sensor 210 in the axial direction X of the stator core 121, as an alternative implementation manner, the air gap detection method provided in the embodiment of the present invention further includes determining the eccentricity of the rotor 110 with respect to the stator 120 according to the final air gap detection value D1 fed back by each of two or more air gap sensors 20, where the two or more air gap sensors 20 are spaced apart from each other in the axial direction X of the stator core 121, and the two or more air gap sensors 20 may be the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220 spaced apart in the axial direction X in the example shown in fig. 11.
Since the rotor 110 and the stator 120 are sleeved and coaxially disposed in a normal state, the axes of the rotor 110 and the stator 120 should be parallel to each other and coincide with each other, that is, the air gap between the rotor 110 and the stator 120 is uniform, and the final air gap detection value D1 fed back by the two or more air gap sensors 20 (i.e., the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220) arranged in the axial direction X should be equal.
When the generator 10 is operated to rotate the rotor 110 and the stator 120 relatively, the rotor 110 and the stator 120 may be eccentric due to machining, assembly error, vibration, and the like, the axes of the rotor 110 and the stator 120 may form an intersecting state shown in fig. 13 from the overlapping state shown in fig. 2, through the deviation between the final air gap detection values D1 fed back by the two or more air gap sensors 20 (i.e. the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220) arranged oppositely and spaced in the axial direction X, therefore, whether the rotor 110 deflects relative to the stator 120 can be known, the eccentricity of the rotor 110 relative to the stator 120 can be obtained, the use safety of the generator 10 can be better monitored, to further optimize the air gap between the rotor 110 and the stator 120 according to the eccentricity of the generator 10, which provides a basis for the optimal design of the generator 10 and reducing the cost.
In addition, according to the air gap detection method and the wind generating set 100 provided by the embodiments of the invention, each air gap sensor 20 is limited to a flat plate type capacitance sensor, so that the accuracy of the detected initial air gap detection value D0 is better and can reach 0.01mm, the air gap variation trend of the generator 10 under each working condition is effectively reflected, and a basis is provided for the design and optimization of the motor. In specific implementation, each air gap sensor 20 can be connected to the stator core 121 in an adhesion mode, the recommended glue types can be factory le tai HY 4090 and RTV-GREY 3145 glue, the adhesion mechanical property and the thermal aging resistance are good, and the requirement of reliable fixation of the sensor can be met. Before the air gap sensor 20 is bonded, the bonding area on the core of the stator 120 needs to be polished by using fine sand vanes 92 and fine sand paper of an angle grinder, the mounting surface is polished to be flat and cleaned, and the polishing area is slightly larger than the bonding area of the air gap sensor 20.
It can be understood that the number and arrangement of the first plate-type capacitive sensors 210 and the second plate-type capacitive sensors 220 are only an optional example, in some other examples, the number of the first plate-type capacitive sensors 210 is not limited to four, and may also be three, five, or even more, the number of the second plate-type capacitive sensors 220 is not limited to one, and may also be more than two, and more than two second plate-type capacitive sensors 220 may be disposed at intervals with one of the first plate-type capacitive sensors 210 in the axial direction X of the stator core 121, and of course, it may also be limited that each second plate-type capacitive sensor 220 and different first plate-type capacitive sensors 210 are disposed at intervals in the axial direction X of the stator core 121, which is not repeated herein.
Referring to fig. 16, fig. 16 is a schematic view illustrating an installation of the adaptor 40 according to the embodiment of the present invention, as an alternative implementation, the stator 120 further includes a vent cover 124 and a filter box 123, the wind turbine further includes an adaptor 40 corresponding to the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220, the adaptor 40 and the stator 120 are connected to the ground, and the adaptor 40 is connected to the filter box 123.
Specifically, the wiring of the air gap sensor 20 is 1.5m, the cable of the first plate type capacitance sensor 210 at four measuring points (12, 3, 6, and 9 o' clock directions) at the tower end 121a of the stator core 121 passes through the gap of the stator coil 122, and when the cable is led out from the back of the vent hole of the stator core 121, the cable is fixed at the vent hole of the stator core 121 by using glue, so that at least 2/3 of ventilation space is reserved to avoid blocking the vent hole, and the cable is led out from the cotton filter hole of the filter box 123. The adapters 40 are fixed to the middle of the filter case 123 by means of a band or a snap ring, and the ground wire of each adapter 40 can be grounded together with the stator 120, but it is also possible to fix the adapter 40 by means of a U-shaped snap ring by punching a hole in the lower end of the vent cover 124.
Optionally, a lead of the second plate type capacitive air gap sensor 220 at a measurement point in the middle of the stator core 121 is led out through a vent hole of the stator core 121, a cable is fixed on a rib plate of the stator bracket by using glue, a through hole with the diameter of 5mm-7mm is punched in the center of the lower right corner of the vent cover plate 124, the cable is placed in the protective clamping sleeve and is placed in the hole, the cable is tensioned, and the cable is fixed firmly by coating the glue.
Since the total number of the first plate-type capacitive sensor 210 and the second plate-type capacitive sensor 220 is five in one example of the invention, five adapters 40 of the invention can also be adopted, and the plugs of the five adapters 40 are all wired to the vicinity of the 9 o' clock direction filter box 123 for fixing, so that the sensor cable can be conveniently and safely wired in the area and then led to the cabinet of the cabin 80 through the cable bracket and the cable groove.
Referring to fig. 17 and 18 together, fig. 17 is a schematic view illustrating an installation of the front end 50 according to the embodiment of the present invention, and fig. 18 is a schematic view illustrating a connection route of the front end 50. As an optional implementation manner, the wind generating set 100 according to the embodiment of the present invention further includes a front-end device 50 disposed in one-to-one correspondence to the adapter 40, the front-end device 50 is installed and integrated in the cabinet 60 of the wind generating set 100, and is adsorbed in the cabinet 60 or outside the cabinet 60 through a strong magnetic four-leg base, a plug of the adapter 40 is connected to a jack at one end, two cables of five cables at one end are connected to a channel 1 (single +) and a channel 2 (single-) of a main controller of the wind generating set 100, one cable is connected to +24VDC, one cable is connected to 0VDC, the last ground wire is connected to GND, signal wires of five measuring points are sequentially connected to the data acquisition module, and 24VDC is used for supplying power, a schematic diagram of a single cable is shown in fig. 16, and the front-end device is connected to the ground wire of the cabinet.
The wind turbine generator system 100 provided by the embodiment of the invention comprises a generator 10, an air gap sensor 20 and a main controller 30, and the main controller 30 can operate the air gap detection method provided by the embodiment of the invention. The obtained final air gap detection value D1 can feed back the air gap of the generator 10 truly, detection of the health level of the generator 10 is facilitated, a basis can be provided for cost reduction development of the generator 10, the dynamic air gap variation trend of the generator 10 can be effectively monitored, and guiding suggestions are provided for a unit control strategy.
It can be understood that the air gap detection method provided by the above embodiments of the present invention is not limited to be used in the generator 10 of the wind turbine generator system 100, and may also be used in air gap detection of a rotor magnetic pole with a rotor coating of a generator in other fields, which is not described herein again.
Referring to fig. 19, fig. 19 is a schematic structural diagram illustrating an air gap detection system according to an embodiment of the present invention, and an air gap monitoring system according to an embodiment of the present invention includes a wind turbine generator system 100, a centralized controller 200, and a cloud server 300 according to the above embodiments. The main controller 30 of the wind turbine generator set 100 sends the final air gap detection value D1 to the central controller 200. The centralized controller 200 stores and uploads the final air gap detection value D1, and the cloud server 300 is used for receiving and storing the final air gap detection value D1, so that a fan manager is installed in a personal PC, an IP address of the same network segment as the main controller 30 of the wind generating set 100 is set, air gap data of each measuring point is continuously acquired for a long time, and the air gap variation range and trend are monitored in real time. The air gap variation trend of the generator 10 under various working conditions is effectively reflected, and a basis is provided for the design and optimization of the generator 10.
Meanwhile, based on the bus topology structure of the beckhoff controller of the megawatt direct-drive wind generating set 100, an air gap monitoring system based on the main controller 30 of the wind generating set 100 is developed, seamless access of the state monitoring system and the fan control system is achieved, and the air gap monitoring system can have the following advantages:
1. characteristic parameter extraction: and the true synchronization of the operation data of the wind generating set and the final air gap detection value is realized, and the operation data and the final air gap detection value are jointly stored and uploaded to the centralized controller 200 at regular time.
2. And (3) system expansion and upgrading: for the requirements of fine diagnosis or extra measurement, system hardware is easy to expand, and with the continuous improvement of data accumulation and state monitoring technology, an analysis algorithm can be issued in a program-controlled manner and is easy to iterate.
3. And (3) state judgment and evaluation: the deterioration trend can be judged according to historical data change trend analysis, early warning is provided, and the risk of further damage of the wind generating set is reduced.
4. And (3) reliable data management: the system automatically stores the monitoring data to form a historical database (a time, day, month and year database).
5. And (3) state monitoring range: condition monitoring is generally a process of monitoring and measuring information (such as air gaps, operating condition data, etc.) of the unit operating conditions, and thus determining whether the unit operating conditions are normal.
While the invention has been described with reference to a preferred embodiment, various modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In particular, the technical features mentioned in the embodiments can be combined in any way as long as there is no structural conflict. It is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (13)
1. An air gap detection method for a generator (10), the method comprising:
obtaining an initial air gap detection value according to an air gap sensor (20), wherein the air gap sensor (20) is arranged between a stator (120) and a rotor (110) of the generator (10), and the air gap sensor (20) is arranged on the surface of a stator iron core (121) facing the rotor (110) to detect an air gap between the stator (120) and the rotor (110);
obtaining an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between a preset air gap detection value and a sensing error caused by a rotor coating (112);
and compensating the initial air gap detection value by using the error compensation value to obtain a final air gap detection value between the stator (120) and the rotor (110).
2. The method of claim 1, wherein the final air gap detection value is equal to a sum of the initial air gap detection value and the corresponding error compensation value.
3. The method of claim 1, further comprising: and obtaining a detection value of the air gap between the stator (120) and the rotor cladding (112) according to the thickness of the rotor cladding (112), the initial air gap detection value and the error compensation value.
4. The method of claim 3, wherein the step of deriving a measured value of the air gap between the stator (120) and the rotor coating (112) from the thickness of the rotor coating (112), the initial measured value of the air gap, and the error compensation value comprises:
calculating a sum of the error compensation value and the initial air gap detection value;
and taking the difference value of the sum value and the thickness of the rotor coating (112) as the air gap detection value between the stator (120) and the rotor coating (112).
5. The method according to any one of claims 1-4, wherein a correspondence between the preset air gap detection value and a sensing error due to the rotor coating (112) is determined from a first correspondence and a second correspondence;
wherein the first corresponding relation is a corresponding relation between an air gap detection value and a preset air gap set under the condition that the rotor (110) has the rotor coating (112); the second corresponding relation is the corresponding relation between the air gap detection value and the preset air gap set under the condition that the rotor (110) has no rotor coating (112).
6. The method according to any one of claims 1-4, wherein the step of obtaining an initial air gap detection value from an air gap sensor (20) comprises:
obtaining a sampling wave of the air gap sensor (20);
carrying out waveform analysis on the sampling wave to obtain a value of an electric signal corresponding to the sampling wave;
and obtaining the initial air gap detection value according to the calibration relation between the preset electric signal value and the air gap detection value.
7. The method according to any one of claims 1-4, further comprising:
and determining the eccentricity of the rotor (110) relative to the stator (120) according to the final air gap detection value fed back by each of two or more air gap sensors (20), wherein the two or more air gap sensors (20) are arranged at intervals in the axial direction (X) of the stator core (121).
8. A wind power plant (100), comprising:
a generator (10) comprising a rotor (110) and a stator (120) which are in running fit, wherein the stator (120) comprises a stator core (121) and a stator coil (122) which are connected with each other, and the rotor (110) comprises a rotor magnetic pole (111);
an air gap sensor (20), the air gap sensor (20) being disposed between the stator (120) and the rotor (110), the air gap sensor (20) being disposed on a surface of the stator core (121) facing the rotor (110) to detect an air gap between the stator (120) and the rotor (110);
and the main controller (30) obtains an initial air gap detection value according to the air gap between the stator (120) and the rotor (110) detected by the air gap sensor (20), obtains an error compensation value corresponding to the initial air gap detection value according to the corresponding relation between a preset air gap detection value and a sensing error caused by a rotor coating (112), and compensates the initial air gap detection value by using the error compensation value to obtain a final air gap detection value between the stator (120) and the rotor (110).
9. Wind park (100) according to claim 8, wherein the air gap sensor (20) comprises a plurality of first plate-like capacitive sensors (210) arranged at intervals in the circumferential direction (Y) of the stator core (121) on the stator core (121) and at least one second plate-like capacitive sensor (220) arranged at intervals with one of the first plate-like capacitive sensors (210) in the axial direction (X) of the stator core (121), the first plate-like capacitive sensor (210) and the second plate-like capacitive sensor (220) each facing the rotor pole (111);
a plurality of first plate-type capacitance sensors (210) are provided near the ends of the stator core (121) in the axial direction (X), and lead wires (210a) of the first plate-type capacitance sensors (210) are passed through gaps of the stator coil (122); and/or the second plate-type capacitance sensor (220) is positioned in the middle or the position close to the middle of the stator core (121) in the axial direction (X), and a lead wire (220a) of the second plate-type capacitance sensor (220) passes through a vent hole of the stator core (121) and intersects with a lead wire (210a) of the first plate-type capacitance sensor (210).
10. Wind park (100) according to claim 9, wherein the stator (120) further comprises a ventilation flap (124) and a filter box (123), the wind park further comprising an adapter (40) in one-to-one correspondence with the first plate capacitive sensor (210) and the second plate capacitive sensor (220), the adapter (40) being jointly grounded with the stator (120);
the adapter (40) is connected to the cartridge (123) or the adapter (40) is connected to the vent flap (124) of the stator (120) by a snap fit.
11. Wind park (100) according to any of claims 8-10, wherein the wind park (100) is a horizontal axis wind generator.
12. Wind park (100) according to claim 9 or 10, wherein the rotor (110) is arranged outside the stator (120), the rotor (110) and the stator (120) being connected at one end in the axial direction (X) by a slew bearing, the plurality of first plate-type capacitive sensors (210) being located at the end of the stator core (121) remote from the slew bearing, the rotor poles (111) comprising permanent magnets.
13. An air gap monitoring system, comprising: the wind power generation set (100) of any of claims 8 to 12, the centralized controller (200) and the cloud server (300);
the main controller (30) of the wind generating set (100) sends the final air gap detection value to the centralized controller (200);
the centralized controller (200) stores and uploads the final air gap detection value;
the cloud server (300) is configured to receive and store the final air gap detection value.
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