CN112267981A - Monitoring device and monitoring method for monitoring bolt loosening state and wind turbine generator - Google Patents
Monitoring device and monitoring method for monitoring bolt loosening state and wind turbine generator Download PDFInfo
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- CN112267981A CN112267981A CN202011261675.3A CN202011261675A CN112267981A CN 112267981 A CN112267981 A CN 112267981A CN 202011261675 A CN202011261675 A CN 202011261675A CN 112267981 A CN112267981 A CN 112267981A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 44
- 238000012806 monitoring device Methods 0.000 title claims abstract description 24
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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
- F03D17/00—Monitoring or testing of wind motors, e.g. diagnostics
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/14—Measuring arrangements characterised by the use of optical techniques for measuring distance or clearance between spaced objects or spaced apertures
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/30—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring angles or tapers; for testing the alignment of axes
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- G—PHYSICS
- G08—SIGNALLING
- G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
- G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link
- G08C17/02—Arrangements for transmitting signals characterised by the use of a wireless electrical link using a radio link
Abstract
The invention discloses a monitoring device and a monitoring method for monitoring bolt loosening state and a wind turbine generator, which belong to the field of bolt loosening prevention and comprise a terminal sensor, a communication controller and a central control room server which are sequentially connected, wherein: the terminal sensor comprises a magnetic encoder and a gap measuring sensor, the magnetic encoder is used for measuring the relative angle between the bolt to be measured and the fixing nut, and the gap measuring sensor is used for recording the gap increment of the clamped part caused by the loosening of the bolt to be measured; the central control room server comprises a display and a controller, the display is used for displaying angle data and gap distance data collected by the terminal sensor, and the controller is used for judging whether the collected data exceed a preset angle and distance threshold value and sending out early warning information according to a judgment result. The invention obtains the bolt pre-tightening state by measuring two key physical quantities, namely the relative angle between the blade bolt and the fixed nut and the gap distance between the clamped parts, and has simple realization and accurate measurement.
Description
Technical Field
The invention relates to the field of bolt looseness prevention, in particular to a monitoring device and a monitoring method for monitoring bolt looseness state and a wind turbine generator.
Background
The wind generating set is used as a large assembly product, and bolt connection is the main connection mode among all parts of the wind generating set. The blade is connected with the wind wheel through the bolt as a core component of the wind turbine generator, but the fixing bolt of the blade is influenced by factors of small maintenance operation space, large pretightening force dispersion degree of the bolt and complex alternating load bearing for a long time, is easy to loosen, and can cause bolt fracture and pitch bearing fracture due to untimely treatment, thereby causing secondary accidents of blade falling.
At present, the bolt fastening state is guaranteed by adopting a mode of manual regular maintenance (1 year) for connecting bolts of the wind generating set, the mode has the defects of time consuming, low efficiency and high cost, the manual regular maintenance can not guarantee the real-time performance of bolt connection fastening degree detection, and the great potential safety hazard exists for the unit operation safety guarantee.
In order to monitor the bolt pre-tightening state in real time and ensure the safety and reliability of the connection of the blades of the unit, different types of bolt pre-tightening state real-time monitoring systems are introduced in the market. Currently, the mainstream monitoring methods include: ultrasonic measurement, pressure washer measurement, image recognition measurement, and the like. However, the ultrasonic measurement method mainly has the defects of high price, complex installation of polishing bolts and active wiring and difficult stress calibration, the pressure washer measurement method mainly has the defect that the whole stress is influenced by the pressure washer added by the disassembled nut, and the image recognition measurement method mainly has the defects of high price, large environment space occupied by sensor arrangement and complex installation of active wiring.
Disclosure of Invention
The invention aims to solve the technical problem of providing a monitoring device for monitoring the bolt loosening state, a magnetic encoder and a wind turbine generator, the monitoring device is low in cost and convenient and fast to construct, the bolt loosening on-line state monitoring can be carried out without changing the original bolt pair structure and the assembly relation, and the objective problem of hidden danger in the conventional blade bolt regular inspection mode can be solved.
In order to solve the technical problems, the technical scheme provided by the invention is as follows:
in one aspect, the invention provides a monitoring device for monitoring a bolt loosening state, which comprises a terminal sensor, a communication controller and a central control room server which are connected in sequence, wherein:
the terminal sensor comprises a magnetic encoder and a gap measuring sensor, the magnetic encoder is used for measuring the relative angle between the bolt to be measured and the fixing nut, and the gap measuring sensor is used for recording the gap increment of the clamped part caused by the loosening of the bolt to be measured;
the communication controller is used for transmitting data acquired by the terminal sensor to the central control room server;
the central control room server comprises a display and a controller, the display is used for displaying angle data and gap distance data collected by the terminal sensor, and the controller is used for judging whether the collected data exceed a preset angle and distance threshold value and sending out early warning information according to a judgment result.
Further, the magnetic encoder includes the encoder body and follows the support, the encoder body is used for connecting the bolt tip that awaits measuring, follow the support include top support and with top leg joint's a plurality of tight landing legs that press from both sides, a plurality of tight landing legs that press from both sides are used for fastening the fixation nut of the bolt that awaits measuring, the top support is connected with the encoder top, it is rotatory along with fixation nut and drive magnetic encoder to follow the support, the encoder body record awaits measuring bolt and fixation nut not hard up rotation angle value.
Further, the encoder body comprises a shell and an angle magnetic encoder positioned in the shell, a hole site is formed in the top of the shell, a top pin assembled with the hole site is arranged on the top support, and a threaded hole used for assembling a bolt to be tested is formed in the bottom of the shell.
Furthermore, still be equipped with lithium cell and zigBee module in the shell, the zigBee module is used for carrying out zigBee wireless transmission with the signal of telecommunication of angle magnetic encoder output.
Further, a rubber member is connected to the inner side of each clamping leg.
Further, the top bracket is hinged with each clamping leg by a pin.
Further, the clamping device also comprises a spring connected between the clamping leg and the top support, and the spring is used for enabling the clamping leg to clamp the fixing nut through the tension of the spring.
Furthermore, the gap measuring sensor comprises an FBG-based fiber bragg grating sensor and an FBG demodulation module, the fiber bragg grating sensor is used for being fixed between the bolt to be measured and the nut clamping piece, and the fiber bragg grating sensor is connected with the FBG demodulation module through a serial port bus;
further, the gap measuring sensor further comprises a lithium battery and a ZigBee module, and the ZigBee module is used for carrying out ZigBee wireless transmission on the displacement change.
Further, the central control room server further comprises a memory and/or a zeroing module.
In another aspect, a method for monitoring a bolt loosening state by using the monitoring device for monitoring a bolt loosening state includes the following steps:
(1) arranging the terminal sensors in the front edge and rear edge regions where the wind power blade bolts are frequently damaged;
(2) sequentially assembling the magnetic encoders on the bolts and the nuts of the blade root in sequence, installing the gap measuring sensors between the variable-pitch bearing and the flange of the blade root corresponding to the positions of the bolts and on the manhole plate near the blade root, connecting the communication controller into a communication ring network of the wind power plant unit through an RJ45 net port, and connecting the central control room server into the communication ring network of the wind power plant unit through an RJ45 net port; monitoring real-time data through a terminal sensor, and transmitting the data to a central control room server through a communication controller;
(3) the central control room server processes and displays data and gives early warning of loosening; and the central control room server collects and displays the terminal sensor data map in real time, judges whether the terminal sensor data exceed a set angle and distance threshold value, and correspondingly gives early warning information.
Further, the magnetic encoder of the terminal sensor in the step (2) records the loosening angle of the blade root bolt and the fixing nut, the fiber grating sensor of the terminal sensor records the increment of the clearance between the clamping piece, the variable pitch bearing and the blade root flange caused by the loosening of the bolt and the nut, and meanwhile, the special working condition of sudden fracture of the blade root bolt can be recorded.
In another aspect, a wind turbine generator set is provided, which includes the monitoring device for monitoring bolt loosening state, wherein,
the magnetic encoder is used for measuring the relative angle between the blade root bolt to be measured and the fixing nut, and the gap measuring sensor is used for recording the increment of the gap between the variable pitch bearing and the blade root flange caused by the looseness of the blade root bolt to be measured.
After adopting such design, the invention has at least the following advantages:
(1) the monitoring device can realize the function of monitoring the pretightening state of the blade bolt in real time, and can effectively avoid the problem that the faults and accidents caused by the bolt looseness cannot be found and processed in time in the conventional regular maintenance mode. The monitoring device has the advantages of accurate measurement, low price of used equipment, small occupied environment space, no change of the structure and the assembly relation of the original bolt pair, and convenient and fast installation and disassembly.
(2) According to the invention, the bolt pre-tightening state is obtained by measuring two key physical quantities, namely the relative angle between the blade bolt and the fixing nut and the gap distance between the clamped parts, so that the method is simple to realize and accurate to measure, and the problems that the stress of bolts is directly measured by ultrasonic waves, pressure washers and the like on the market, and bolt pairs with different specifications are complicated to calibrate and the stress value is inaccurate in the execution process are solved.
(3) The invention adopts the terminal sensor comprising a magnetic encoder at the bolt fixing nut end of the blade and a gap measuring sensor (fiber bragg grating sensor) between a bolt clamping piece-blade root flange and a variable-pitch bearing flange, and the two sensors have the advantages of low price, convenient installation and no change of the structure and the assembly relation of the original bolt pair compared with the bolt stress sensors such as an ultrasonic type sensor, a piezoelectric type sensor (a gasket) and the like on the market.
(4) According to the invention, the power supply of a lithium battery is realized by adopting a terminal sensor, the wireless transmission between the wind wheel and the engine room is realized by signal transmission, the problems that the conventional bolt stress sensors in the market, such as an ultrasonic type bolt stress sensor and a piezoelectric type bolt stress sensor (a gasket), are difficult to fix and protect by using a cable for wired power supply and wired data transmission in the rotating wind wheel, and the communication between the wind wheel and the engine room is difficult to realize under the condition of not influencing a variable pitch system in the wind wheel and a main control system in the engine room of the.
Drawings
The foregoing is only an overview of the technical solutions of the present invention, and in order to make the technical solutions of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and the detailed description.
FIG. 1 is a monitoring schematic diagram of a monitoring device for monitoring bolt loosening state of the present invention;
FIG. 2 is a schematic structural diagram of an embodiment of a monitoring device for monitoring the loosening state of a bolt, which is provided by the invention and is mounted on a bolt to be tested;
FIG. 3 is a schematic structural diagram of one embodiment of a magnetic encoder of the present invention;
FIG. 4 is a cross-sectional schematic view of one embodiment of a magnetic encoder of the present invention;
FIG. 5 is a schematic view of the construction of the follower carriage of the magnetic encoder of the present invention;
fig. 6 is a schematic structural diagram of a fiber grating sensor in the terminal sensor of the present invention.
The system comprises a terminal sensor 1, a cabin communication controller 3, a central control room server 41, bolts 42, fixing nuts 5, a variable pitch bearing 6, a blade root flange 7, a blade root hole plate 11, a magnetic encoder 111 encoder body 1111, a shell 1112, an angle magnetic encoder 1113, a ZigBee module 1114, a button lithium battery 112, a following bracket 1121, a top bracket 1122, a top pin 1123 pin 1124, a spring 1125, a clamping leg 1126, a rubber part 12, a gap measurement sensor 121, an FBG-based fiber bragg grating sensor 122, an FBG demodulation module 123, a square lithium battery 124 and a ZigBee module.
Detailed Description
Exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the invention are shown in the drawings, it should be understood that the invention can be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
The present invention provides an embodiment of a monitoring device for monitoring a bolt loosening state, as shown in fig. 1 to 6, comprising a terminal sensor 1, a communication controller 2 and a central control room (user end) server 3, which are connected in sequence, wherein: the terminal sensor 1 comprises a magnetic encoder 11 and a gap measuring sensor 12, wherein the magnetic encoder 11 is used for measuring the relative angle between the bolt 41 to be measured and the fixing nut 42, and the gap measuring sensor 12 is used for recording the gap increment (the gap between the variable pitch bearing and the blade root flange) of a clamped piece caused by the looseness of the bolt 41 to be measured; the communication controller 2 is used for transmitting the data acquired by the terminal sensor to the central control server 3; the central control room server 3 comprises a display and a controller, the display is used for displaying angle data and gap distance data collected by the terminal sensor, and the controller is used for judging whether the collected data exceed a preset angle and distance threshold value and sending out early warning information according to a judgment result.
When the wind power station booster station is used, the terminal sensor is positioned in a wind wheel of a wind turbine generator, the communication controller is positioned in a cabin of the wind turbine generator, and a central control room (user side) server is positioned in the booster station of the wind power station; the terminal sensor records two physical quantities of a blade bolt and a fixed nut backspin loosening angle at an appointed position and a gap between a clamped part, a variable pitch bearing and a blade root flange in real time, the cabin communication controller is responsible for collecting and processing data output by the terminal sensor and transmitting monitoring data into the central control room client server in real time through a unit ring network, the central control room server completes analysis and storage of the data through professional analysis software, analyzes a map through the real-time measured value and visually displays whether the bolt is loosened or not and the degree of the bolt is loosened, and sends out early warning information according to the bolt loosening degree.
The specific use method of the monitoring device of the invention is as follows:
(1) arranging the terminal sensors in the front edge and rear edge areas where the wind power blade bolts are frequently damaged, wherein the specific number is based on the number covering the damage history of the blade root bolts of the specific type of the wind power plant;
(2) the magnetic encoders of the terminal sensors are sequentially assembled on the bolts and the bolts of the blade root, the fiber bragg grating sensors of the terminal sensors are installed between the pitch bearing corresponding to the bolt position and the flange of the blade root and on the manhole plate near the blade root, the cabin communication controller is installed on the cabin control cabinet, the wind power plant unit communication ring network is accessed through the RJ45 net port, and finally the central control room user side server is installed in the central control room of the wind power plant booster station and is accessed into the wind power plant unit communication ring network through the RJ45 net port. The terminal sensor monitors real-time data, firstly, the real-time data are wirelessly transmitted to a cabin communication controller with a ZigBee receiver through a ZigBee module configured by a magnetic encoder and a fiber bragg grating sensor, secondly, the cabin communication controller processes the data and transmits the real-time data to a wind power plant unit communication ring network in a TCP/IP mode, and finally, the real-time data are acquired by a user side server of a central control room in the wind power plant unit communication ring network, and data processing, display and loosening early warning are carried out;
(3) and the central control room user side server collects and displays the terminal sensor data map in real time, judges whether the terminal sensor data exceed a set angle and a distance threshold value, gives out early warning information according to needs, timely informs operation and maintenance personnel of carrying out accurate maintenance on the blade root bolt, and carries out recalibration and zero setting after maintenance.
Further, in the step (2), the magnetic encoder of the terminal sensor records the loosening angle of the bolt and the fixed nut of the blade root, the fiber grating sensor of the terminal sensor records the increment of the clearance between the clamping piece and the blade root flange caused by the loosening of the bolt and the nut, and simultaneously can record the special working condition of the loosening angle which is not identified by the magnetic encoder of the terminal sensor and is caused by the sudden breakage of the bolt of the blade root, catch the increment of the clearance between the blade root flange and the blade root bearing after the breakage of the bolt in time, and accurately reflect the running state of the bolt and the nut.
Further, the angle and distance threshold in the step (3) is used for testing the relative counter-rotation angle value of the bolt and the nut when the pre-tightening force of the blade bolts with different specifications does not meet the design requirement through experiments, and recording the increment value of the gap of the clamped part at the moment and calibrating the increment value as the loosening threshold of the bolt of the type.
Furthermore, after the blade root bolt is loosened in the step (3), the operation and maintenance personnel only need to disassemble the loosened bolt and two bolts nearby the loosened bolt and the magnetic encoder of the terminal sensor, namely manually opening the following support in the magnetic encoder of the terminal sensor, then manually screwing out the body in the magnetic encoder, the fiber grating sensor of the terminal sensor does not need to be disassembled due to the fact that the torque is not influenced, then the torque is exerted to restore the pretightening force of the blade root bolt, then the magnetic encoder of the terminal sensor is repeatedly installed, and finally the fiber grating sensor is re-calibrated in the user side server of the central control room, so that the whole bolt loosening maintenance process of disassembling, torque exerting and installing is efficient and convenient.
Several embodiments of the monitoring device of the present invention may be:
A wind power blade bolt looseness prevention monitoring system comprises a terminal sensor 1, an engine room communication controller 2 and a central control room user side server 3. The terminal sensor 1 is positioned in a wind wheel of the wind turbine generator, the cabin communication controller 2 is positioned in a cabin of the wind turbine generator, and the user side server 3 of the central control room is positioned in a booster station of a wind power plant; the terminal sensor 1 records two physical quantities, namely a blade bolt and a fixed nut backspin loosening angle at an appointed position and a gap between a clamped part, a variable pitch bearing and a blade root flange in real time, the cabin communication controller 2 is responsible for collecting and processing data output by the terminal sensor 1, transmits monitoring data into the central control room client server 3 in real time through a unit ring network, and the central control room server 3 completes analysis and storage of the data through professional analysis software, analyzes a map by displaying whether the bolt is loosened and loosed through real-time measured values and sends out an early warning signal according to the loosening degree.
Further, the terminal sensor 1 comprises a magnetic encoder 11 for measuring the back-rotation loosening angle of the bolt and the nut, and a fiber bragg grating sensor 12 for measuring the gap between the blade bolt, the nut clamping piece, the pitch bearing and the blade root flange.
Further, magnetic encoder 11 of terminal sensor comprises encoder body 111 and follow support 112, and encoder body 111 connects the blade root bolt, follows support 112 and connects magnetic encoder rotary part and the fixation nut of fastening blade root bolt in encoder body 111, follows support 112 and can drive magnetic encoder rotary part along with the fixation nut is rotatory, and magnetic encoder 11 records the not hard up rotation angle value of blade root bolt and fixation nut.
Specifically, the magnetic encoder body 111 of the terminal sensor is composed of a shell 1111 made of engineering plastics and used for packaging an angle magnetic encoder 1112, and a hole position is configured at the top of the shell 1111 and used for connecting a rotating component of the angle magnetic encoder 1112 along with the bracket 112; the bottom of the housing 1111 is provided with 2-3p threaded holes for attaching blade bolts.
Specifically, the angle magnetic encoder 1112 in the magnetic encoder body 111 of the terminal sensor is powered by a button-type lithium battery 1114, a ZigBee module 1113 is added, and the magnetic encoder outputs an electric signal to perform ZigBee wireless transmission, and the magnetic encoder and the ZigBee are packaged in the shell 1111.
Specifically, the magnetic encoder following bracket 112 of the terminal sensor is composed of a top tripod 1121, a top pin 1122, a pin 1123, a spring 1124, a clamping leg 1125 and a rubber part 1126, wherein the top tripod 1121 and the top pin 1122 are fixedly welded, the clamping leg 1125 is hinged to the top tripod 1121 through the pin 1123, the spring 1124 is connected with the top tripod 1121 and the clamping leg 1125, and the rubber part 1126 is connected with the clamping leg 1125 in a gluing mode; the top pin 1122 is used to connect the magnetic encoder rotation components in the magnetic encoder 11 of the end sensor, and the clamping leg 1125 and rubber 1126 are used to grip the three faces of the blade bolt retention nut under the tension of the spring 1124.
Further, the gap measuring sensor 12 of the terminal sensor is composed of a fiber bragg grating displacement sensor 121 based on an FBG (fiber bragg grating) and an FBG demodulation module 122, and the fiber bragg grating displacement sensor 121 of the FBG is fixed between a blade root bolt and a nut clamping piece, namely a pitch bearing and a blade root flange, and measures the gap distance between the blade root bolt and the nut clamping piece, namely the pitch bearing and the blade root flange.
Specifically, the FBG fiber bragg grating displacement sensor 121 is parallel to the blade bolt and is adhered between the variable pitch bearing and the blade root flange by industrial glue, the FBG demodulation module 122 is fixed on the blade root manhole plate, and a 485 serial port bus communication mode is adopted between the FBG fiber bragg grating displacement sensor 121 and the blade root flange; the FBG demodulation module 122 is powered by a square lithium battery 123, a ZigBee module 124 is added, the detected displacement is converted into an electric signal to carry out ZigBee wireless transmission, and the electric signal and the ZigBee wireless transmission are packaged in the FBG demodulation module 122.
Further, the cabin communication controller 2 is composed of an industrial gateway, has functions of ZigBee signal receiving and Ethernet, is provided with an RJ45 network port, is used for receiving monitoring data of the terminal sensor 1 in the wind wheel, and is connected into a communication ring network of the wind power plant unit to perform data transmission in a TCP/IP mode.
Furthermore, the user side server 3 of the central control room is composed of an industrial personal computer based on win10, and is configured with professional analysis software to store and process the feedback data of the terminal sensor 1 in the ring network.
Specifically, the central control room user side server 3 displays a map of values of loosening angles of bolts and nuts of the blade root and distance values of gaps between the clamped part, the variable pitch bearing and the blade root flange, analyzes, compares and stores whether data of the terminal sensor 1 exceed a set angle and a distance threshold value, and sends out bolt loosening early warning information if the data exceed the set angle and the distance threshold value, so that operation and maintenance personnel are informed to carry out fixed-point maintenance on the loosened bolts.
Specifically, the central control room user side server 3 has the function of resetting the terminal sensor 1 to zero, and is used for resetting the measurement value after the terminal sensor is detached and mounted again when the bolt is loosened.
The present embodiment provides a monitoring method of the monitoring device for monitoring bolt loosening according to embodiment 1, including the steps of:
(1) arranging the terminal sensors 1 in the front edge and rear edge regions where the wind power blade bolts are frequently damaged, wherein the specific number is based on the number covering the damage history of the blade root bolts of the specific type of the wind power plant;
(2) sequentially assembling the magnetic encoders 11 of the terminal sensors 1 on the bolts and the bolts of the blade root, installing the gap measuring sensors 12 of the terminal sensors 1 between the pitch bearing corresponding to the bolt position and the flange of the blade root and on the manhole plate near the blade root, installing the cabin communication controller 2 on the cabin control cabinet, accessing the communication ring network of the wind power plant unit through the RJ45 net port, and finally installing the user side server 3 of the central control room in the central control room of the wind power plant booster station, and accessing the communication ring network of the wind power plant unit through the RJ45 net port. The terminal sensor 1 monitors real-time data, firstly, the real-time data are wirelessly transmitted to a cabin communication controller 2 with a ZigBee receiver through ZigBee modules 1113 and 124 configured by a magnetic encoder 11 and a fiber bragg grating sensor 12, secondly, the cabin communication controller 2 processes the data and transmits the real-time data to a wind power plant unit communication ring network in a TCP/IP mode, and finally, the real-time data are acquired by a user side server 3 of a central control room in the wind power plant unit communication ring network and are subjected to data processing, display and loosening early warning;
(3) and the central control room user side server 3 collects and displays the data map of the terminal sensor 1 in real time, judges whether the data of the terminal sensor 1 exceeds a set angle and a distance threshold value, gives out early warning information according to needs, timely informs operation and maintenance personnel to accurately overhaul a blade root bolt, and after the overhaul, the central control room user side server 3 executes the re-calibration zero-setting.
Further, in the step (2), the magnetic encoder 11 of the terminal sensor 1 records the loosening angle of the bolt and the fixed nut of the blade root, the gap measuring sensor 12 of the terminal sensor 1 records the increase of the gap between the clamping piece, the pitch bearing and the flange of the blade root, caused by the loosening of the bolt and the nut, and simultaneously can record the special working condition of the loosening angle which is not identified by the magnetic encoder 11 of the terminal sensor 1 and is caused by the sudden breakage of the bolt of the blade root, catch the increase of the gap between the pitch bearing and the flange of the blade root after the bolt is broken in time, and accurately reflect the running state.
Further, the angle and distance threshold in the step (3) is used for testing the relative counter-rotation angle value of the bolt and the nut when the pre-tightening force of the blade bolts with different specifications does not meet the design requirement through experiments, and recording the increment value of the gap of the clamped part at the moment and calibrating the increment value as the loosening threshold of the bolt of the type.
Furthermore, after the root bolt is loosened in the step (3), the operation and maintenance personnel only need to disassemble the loosened bolt and two bolts nearby the loosened bolt from the magnetic encoder 11 of the terminal sensor 1, namely manually opening the following support 112 in the magnetic encoder 11 of the terminal sensor 1, then manually screwing out the body 111 in the magnetic encoder 11, the gap measuring sensor 12 of the terminal sensor 1 does not need to be disassembled because the striking torque is not affected, then striking the torque to recover the pretightening force of the root bolt, then repeatedly installing the magnetic encoder 11 of the terminal sensor 1, and finally re-calibrating the gap measuring sensor in the user side server 3 of the central control room, so that the whole bolt loosening maintenance process of disassembling, striking the torque and installing is efficient and convenient.
When the device is used, a plurality of terminal sensors 1 can be arranged in the front edge and rear edge regions of the frequent failure of the blade bolt of the wind turbine generator, a single wind turbine generator comprises three blades, three sets of terminal sensors 1 are assembled, then a nacelle communication controller 2 is assembled on a nacelle control cabinet of the single wind turbine generator, the loosening monitoring data of the three blade bolts of the set is collected and is connected into a wind turbine generator communication ring network, the rest wind turbine generators are assembled with the terminal sensors 1 and the nacelle communication controller 2 in the same way and in the same quantity, finally a central control room user terminal server 3 is installed in a central control room of a wind turbine generator booster station, is connected into the wind turbine generator communication ring network of the wind turbine generator station, receives the loosening monitoring data of the blade bolts of all the wind turbine generator station, processes the data, and displays the loosening angle value of the bolts and the distance between a clamped part, a pitch, and an alarm is given for the loosened bolt.
The invention has the advantages of low equipment price, simple and convenient assembly and maintenance operation, no influence on the original structure and assembly relation of the blade bolt pair, no dependence on and influence on the original pitch system in the wind wheel of the unit and the main control system in the cabin in the power supply of the sensor lithium battery and the wireless data transmission, realization of the monitoring of the looseness of the blade bolt of the wind turbine generator of the whole wind power plant, timely and accurate discovery of the bolt looseness fault, implementation of accurate maintenance treatment, maintenance-free mode when the blade bolt is opened and no alarm is given, reduction of the manpower and material costs of bolt maintenance work, effective avoidance of the occurrence of the accidents of the bolt looseness, untimely fracture of the pitch bearing and blade falling caused by the fracture treatment, and great.
The invention also has the following beneficial effects:
(1) according to the invention, the bolt pre-tightening state is obtained by measuring two key physical quantities, namely the relative angle between the blade bolt and the fixed nut and the gap distance between the clamped parts, so that the method is simple to realize and accurate to measure;
(2) the sensor adopted by the invention has the advantages of low price, convenient installation and disassembly and no change of the structure and the assembly relation of the original bolt pair;
(3) according to the invention, the power supply of the lithium battery is realized by adopting the terminal sensor, the wireless transmission between the wind wheel and the engine room is realized by signal transmission, and the problem of difficult communication between the wind wheel and the engine room is solved under the condition that a variable pitch system in the wind wheel and a main control system in the engine room of the original unit are not influenced;
(4) the invention changes the existing planned maintenance mode of the blade bolt, realizes the maintenance-free accurate maintenance mode of the blade bolt without alarming, and effectively reduces the maintenance cost of the bolt at the key position of the wind turbine generator.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the present invention in any way, and it will be apparent to those skilled in the art that the above description of the present invention can be applied to various modifications, equivalent variations or modifications without departing from the spirit and scope of the present invention.
Claims (10)
1. The utility model provides a monitoring devices for monitoring bolt looseness state which characterized in that, is including the terminal sensor, communication controller and the central control room server that connect gradually, wherein:
the terminal sensor comprises a magnetic encoder and a gap measuring sensor, the magnetic encoder is used for measuring the relative angle between the bolt to be measured and the fixing nut, and the gap measuring sensor is used for recording the gap increment of the clamped part caused by the loosening of the bolt to be measured;
the communication controller is used for transmitting data acquired by the terminal sensor to the central control room server;
the central control room server comprises a display and a controller, the display is used for displaying angle data and gap distance data collected by the terminal sensor, and the controller is used for judging whether the collected data exceed a preset angle and distance threshold value and sending out early warning information according to a judgment result.
2. The device for monitoring the bolt loosening state according to claim 1, wherein the magnetic encoder comprises an encoder body and a following support, the encoder body is used for being connected to the end portion of the bolt to be detected, the following support comprises a top support and a plurality of clamping legs connected with the top support, the plurality of clamping legs are used for fastening a fixing nut of the bolt to be detected, the top support is connected with the top of the encoder, the following support can rotate along with the fixing nut and drive the magnetic encoder to rotate, and the encoder body records the loosening rotation angle value of the bolt to be detected and the fixing nut.
3. The device as claimed in claim 2, wherein the encoder body comprises a housing and an angular magnetic encoder inside the housing, the top of the housing is provided with a hole site, the top bracket is provided with a top pin fitted with the hole site, and the bottom of the housing is provided with a threaded hole for fitting to a bolt to be tested.
4. The monitoring device for monitoring the bolt loosening state according to claim 3, wherein a lithium battery and a ZigBee module are further arranged in the shell, and the ZigBee module is used for carrying out ZigBee wireless transmission on the electric signal output by the angle magnetic encoder.
5. The monitoring device for monitoring the bolt loosening state according to any one of claims 2 to 4, wherein a rubber member is connected to the inner side of each clamping leg;
and/or the top bracket is hinged with each clamping leg through a pin;
and/or, a spring connected between the clamping leg and the top bracket for enabling the clamping leg to clamp the fixing nut through the tension of the spring.
6. The monitoring device for monitoring the bolt loosening state according to any one of claims 1 to 5, wherein the gap measuring sensor comprises an FBG-based fiber bragg grating sensor and an FBG demodulation module, the fiber bragg grating sensor is used for being fixed between the bolt to be detected and the nut clamping piece, and the fiber bragg grating sensor and the FBG demodulation module are connected through a serial port bus;
and/or, the clearance measuring sensor also comprises a lithium battery and a ZigBee module, and the ZigBee module is used for carrying out ZigBee wireless transmission on the displacement change.
7. The monitoring device for monitoring bolt loosening state according to any one of claims 1 to 6, wherein the central control room server further comprises a memory and/or a zeroing module.
8. A method of monitoring a bolt loosening state, using the monitoring device for monitoring a bolt loosening state according to any one of claims 1 to 7, comprising the steps of:
(1) arranging the terminal sensors in the front edge and rear edge regions where the wind power blade bolts are frequently damaged;
(2) sequentially assembling the magnetic encoders on the bolts and the nuts of the blade root in sequence, installing the gap measuring sensors between the variable-pitch bearing and the flange of the blade root corresponding to the positions of the bolts and on the manhole plate near the blade root, connecting the communication controller into a communication ring network of the wind power plant unit through an RJ45 net port, and connecting the central control room server into the communication ring network of the wind power plant unit through an RJ45 net port; monitoring real-time data through a terminal sensor, and transmitting the data to a central control room server through a communication controller;
(3) the central control room server processes and displays data and gives early warning of loosening; and the central control room server collects and displays the terminal sensor data map in real time, judges whether the terminal sensor data exceed a set angle and distance threshold value, and correspondingly gives early warning information.
9. The method for monitoring the bolt loosening state according to claim 8, wherein in the step (2), the magnetic encoder of the terminal sensor records the loosening angle of the bolt and the fixed nut at the blade root, the fiber grating sensor of the terminal sensor records the increment of the clearance between the clamping piece-variable pitch bearing and the flange at the blade root caused by the loosening of the bolt and the nut, and simultaneously records the special working condition of sudden fracture of the bolt at the blade root.
10. Wind turbine comprising a monitoring device for monitoring bolt loosening according to any of claims 1 to 7, wherein,
the magnetic encoder is used for measuring the relative angle between the blade root bolt to be measured and the fixing nut, and the gap measuring sensor is used for recording the increment of the gap between the variable pitch bearing and the blade root flange caused by the looseness of the blade root bolt to be measured.
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| CN113883016A (en) * | 2021-11-16 | 2022-01-04 | 西安热工研究院有限公司 | Real-time monitoring method and system for blade root bolt fracture of wind generating set blade |
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| CN114739560A (en) * | 2022-03-10 | 2022-07-12 | 深圳市风行太保科技有限公司 | Fastening device, threaded fastener monitoring method, device, system and storage medium |
| CN114739560B (en) * | 2022-03-10 | 2024-02-27 | 深圳市风行太保科技有限公司 | Fastening device, threaded fastener monitoring method, device, system and storage medium |
| CN114941610A (en) * | 2022-06-27 | 2022-08-26 | 上海拜安传感技术有限公司 | Monitoring method and monitoring system for bolts at root of fan blade |
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