CN112477195A - Intelligent monitoring system for wind power blade assembly mold - Google Patents
Intelligent monitoring system for wind power blade assembly mold Download PDFInfo
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- CN112477195A CN112477195A CN202011085240.8A CN202011085240A CN112477195A CN 112477195 A CN112477195 A CN 112477195A CN 202011085240 A CN202011085240 A CN 202011085240A CN 112477195 A CN112477195 A CN 112477195A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
- B29C33/04—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
- B29L2031/085—Wind turbine blades
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Wind Motors (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention relates to an intelligent monitoring system for a wind power blade assembly mold, which comprises a sensor, a signal acquisition and transmission system and a control system, wherein the sensor is connected with the signal acquisition and transmission system; the sensors comprise a vacuum degree sensor, a temperature sensor and a plurality of laser displacement sensors, and the laser displacement sensors are used for detecting the width of the die closing seam and the axial and chordwise dislocation degree of the die closing seam; the vacuum degree sensors comprise a plurality of vacuum degree sensors which are respectively arranged on the vacuum-pumping pipelines at the rear edges of the upper die and the lower die; the temperature sensor comprises a plurality of thermal resistors which are pre-embedded on the surfaces of the upper die and the lower die, and the thermal resistors are uniformly distributed on the whole surfaces of the upper die and the lower die; the upper die and the lower die are divided into a plurality of areas, each area is provided with a data acquisition module, each data acquisition module is used for acquiring sensor data of the area nearby and sending the sensor data to an upper computer of the control system, and the upper computer monitors and displays the sensor data in real time. The invention carries out comprehensive and centralized online feedback on the parameters of the die and improves the production efficiency and the product quality.
Description
Technical Field
The invention relates to the technical field of wind power blade assembly production, in particular to an intelligent monitoring system for a wind power blade assembly mold.
Background
At present, a wind power blade assembly is produced by adopting a mold vacuum infusion molding technology, a vacuum pump and a heater are required to be used in a vacuum infusion process, and the mold relates to operations such as overturning, mold closing and the like. Because the wind power blade subassembly size is very big, in the production site, vacuum pump, heater etc. are dispersed and are arranged in different places, and the working parameter of vacuum pump and heater also all has independent instrument respectively to show, this just leads to the parameter that an operating personnel can not in time monitor each instrument. For example, vacuum negative pressure must be ensured to meet the requirements during the perfusion process. Because each equipment dispersion is everywhere in production place, when taking place the vacuum and revealing, operating personnel often is difficult in time to discover.
Summarizing, the following problems mainly exist:
(1) the heaters, the vacuum pump, the hydraulic turnover device and other equipment are distributed, so that the occupied space is large; the working parameters of each device are independently controlled and displayed, and a centralized monitoring platform is lacked. Workers need to visually check numerical values of field instruments and equipment and record the numerical values in a form handwriting mode, and therefore labor intensity is high and labor cost is high.
(2) The real reasons of the product problems in the production process cannot be found in time due to the lack of the functions of real-time monitoring of the mold parameters, data collection and feedback in the production process and insufficient data support. Many process defects can only be resolved or process optimized through trial and error and trial and error.
(3) The water heating mould can be controlled in a subarea mode, but at present, the water heating mould is only limited to the display of the temperature of inlet water and return water of a heater, the real-time feedback of the temperature of each area of the mould is lacked, and no early warning is given when the local temperature of the mould is abnormal.
(4) In addition, for the gap of a mold closing seam and the dislocation of the mold closing after the mold is turned over and closed, the existing monitoring system also has no on-line monitoring function, needs manual inspection, has high labor intensity, increases the time required by production and has the risk of missing inspection.
At present, some related practitioners propose parameter monitoring technical schemes, but most of the schemes are relatively small in application range, are limited to a certain specific parameter, lack of certain generality and systematicness, lack of integration and analysis of various parameters, and are difficult to meet the requirements of parameter early warning and process upgrading and the production mode of production line digitization and intelligence.
Disclosure of Invention
Technical problem to be solved
In view of the problems in the prior art, the invention provides an intelligent monitoring system for a wind power blade assembly mold, which can be used for carrying out centralized acquisition and feedback on a plurality of parameters of the mold in the production of the wind power blade assembly, replaces the current modes of decentralized display and feedback, manual instrument checking and parameter recording, meets the production requirements, simultaneously improves the production efficiency and reduces the risk of blade scrapping caused by parameter abnormity, and simultaneously correspondingly provides a solution for the problem that the current real-time feedback of the temperature of each area of the mold is lacked, and the problem that the gap of a mold closing seam and the dislocation of the mold closing after the mold is turned and closed can not be monitored on line.
(II) technical scheme
In order to achieve the purpose, the invention adopts the main technical scheme that:
in a first aspect, the invention relates to an intelligent monitoring system for a wind power blade assembly mold, which comprises a sensor, a signal acquisition and transmission system and a control system;
the wind power blade assembly mold is a wind power blade mold, a blade root mold, a web plate mold or a blade main beam mold;
the control system comprises an upper computer;
the sensor comprises a vacuum degree sensor, a temperature sensor and a laser displacement sensor; the laser displacement sensors are used for detecting the width of the die closing seam, the axial dislocation degree and the chord direction dislocation degree of the die closing seam; the vacuum degree sensors comprise a plurality of vacuum degree sensors which are respectively arranged on the vacuum-pumping pipelines at the rear edges of the upper die and the lower die; the temperature sensor comprises a plurality of thermal resistors which are pre-embedded on the surfaces of the upper die and the lower die, and the thermal resistors are uniformly distributed on the whole surfaces of the upper die and the lower die;
the signal acquisition and transmission system comprises a data acquisition module; the upper die and the lower die of the die are divided into a plurality of areas, each area is provided with a data acquisition module, and the data acquisition modules in each area are used for acquiring data of all sensors in the area and sending the data to an upper computer of the control system;
the upper computer calibrates the data of each sensor according to the measuring range according to the received sensor data;
the algorithm for the data of the vacuum degree sensor and the laser displacement sensor is as follows:
wherein, for the data of the temperature sensor, the algorithm is as follows:
the upper computer runs the monitoring software, and can display the temperature value and the vacuum value measured by the sensors in the upper die and the lower die on the monitoring interface of the monitoring software.
According to a preferred embodiment of the present invention, the laser displacement sensor includes a first detector for detecting a width of the clamping gap, a first reflector is mounted on an edge of one of the upper mold and the lower mold, a first detector is mounted on an edge of the other of the upper mold and the lower mold, laser light emitted from the first detector is irradiated on the first reflector, reflected by the first reflector and received by the first detector, and the width of the clamping gap between the upper mold and the lower mold is sensed by the first detector.
Preferably, the first reflector is mounted on the PS side of the mold and the first detector is mounted on the SS side of the mold. Because the first reflector can normally work without wiring circuits, the first reflector is simple to install and is installed on the PS surface, the installation mode can avoid the interference of the circuits when the PS surface is turned over, and the SS surface of the die is not turned over. And after the die is closed, the first detector automatically detects the width value of the closed die gap.
Preferably, the outer sides of the first detector and the first reflector are respectively provided with a protective cover, the protective cover is not combined with the support of the first detector and is not combined with the first reflector, and detection errors caused by shaking of the protective cover can be avoided.
According to the preferred embodiment of the invention, the laser displacement sensor comprises a second detector for detecting the axial dislocation degree and the chord-wise dislocation degree of the matched die seam; the second detector is arranged beside the jacking cylinder, and a second reflector is also arranged beside the jacking cylinder; the second detector is arranged on the PS surface of the mould, and the second reflector is arranged on the SS surface of the mould; the laser emitting and receiving end of the second detector corresponds to the second reflector; the axial dislocation degree and the chordwise dislocation degree of the mold closing seam can be detected and detected by the second detector and the second reflector.
According to the preferred embodiment of the invention, the number of the thermal resistors is at least 52, the thermal resistors are pre-embedded on the PS surface and the SS surface of the mold during production and manufacturing of the mold, at least 26 thermal resistors are respectively arranged on the PS surface and the SS surface of the mold, and the thermal resistors are uniformly dispersed on the whole surfaces of the PS surface and the SS surface of the mold and used for monitoring the temperature of different positions of the mold.
According to the preferred embodiment of the invention, the number of the vacuum degree sensors is at least 13, one of the vacuum degree sensors is arranged on the vacuum-pumping pipeline, and the other vacuum degree sensors are arranged at a vacuum position and a vacuum position of the rear edge of the upper die and the rear edge of the lower die; at least 3 vacuum installations are arranged on one side of the rear edge of the upper die, at least 3 vacuum installations are arranged on the other side of the rear edge of the upper die, at least 3 vacuum installations are arranged on one side of the rear edge of the lower die, and at least 3 vacuum installations are arranged on the other side of the rear edge of the lower die.
According to the preferred embodiment of the invention, the first detector and the first reflector at least comprise 10 sets, wherein at least 5 sets are arranged at the front edge of the mould, and at least 5 sets are arranged at the rear edge of the mould for detecting the width of the closed mould seam; the second detector and the second reflector at least comprise 2 sets of reflectors which are arranged beside the jacking cylinder and used for detecting the axial dislocation degree and the chordwise dislocation degree of the die closing seam.
According to the preferred embodiment of the invention, the upper die and the lower die of the die are respectively divided into 2 areas, the total number of the areas is 4, and each area is internally provided with a data acquisition module which is used for acquiring data of all sensors in the area where the data acquisition module is located.
According to the preferred embodiment of the invention, the data acquired by the data acquisition module is transmitted by adopting an MODBUS TCP protocol, the IP addresses of the data acquisition module and an upper computer of the control system are arranged in the same network segment and are connected to the same switch in a wired or wireless manner, the upper computer is set as a client to be in a reading mode, is connected with the data acquisition module of each area in a circulating access manner by pointing to different IP addresses, and stores the data of the register area of the switch into different data blocks of the upper computer. Preferably, the operation, fault signals and other important equipment parameters of the heater, the vacuum pump and the hydraulic turnover control cabinet are also sent to the upper computer in a wiring or Ethernet communication mode.
According to the preferred embodiment of the invention, the control system comprises the upper computer, the switch, an industrial personal computer, necessary switches, display lamps, an alarm and other equipment.
According to the preferred embodiment of the invention, the monitoring interface of the upper computer comprises graphs corresponding to the PS surface and the SS surface of the mold, and data frames for displaying the detection values of the corresponding position sensors are arranged on the graphs corresponding to the positions of the vacuum degree sensor, the temperature sensor and the laser displacement sensor arranged on the mold.
According to the preferred embodiment of the invention, the monitoring software can set upper and lower parameter limits according to the process requirements, the upper and lower parameter limits comprise upper limit of a die-closing seam, upper and lower limits of heating temperature of each stage, upper and lower limits of vacuum pressure and the like, the upper computer judges detection data of each sensor in the production process according to the set upper and lower parameter limits, and when certain detection data exceeds the upper and lower limit ranges, alarm equipment sends out an alarm to remind field personnel, or a data frame at a corresponding position on a graph of a monitoring interface flickers to remind a worker and record alarm time, a measuring point position and a measuring value type.
Preferably, the host computer in the invention can collect and calculate data through PLC, such as Siemens S7-1200 PLC.
(III) advantageous effects
The invention has the beneficial effects that:
the intelligent monitoring system for the wind power blade assembly mold can intuitively and intensively display the temperature of different sites of the mold, the vacuum degree of different positions of the mold, the width of a mold closing seam, the mold closing dislocation degree and other mold parameter conditions in the whole process of producing the wind power blade assembly by the vacuum infusion process to workers, (can also display the operation of a heater, a vacuum pump and a hydraulic turnover control cabinet, fault signals, other important equipment working parameters and other data), only one operator is needed to know whether the working parameters of the mold are within a normal range at any time, and response measures can be made in time. In addition, the monitoring software of the system can also form a historical trend graph, an alarm record and a statistical report for on-site query and printout, and the historical trend graph, the alarm record and the statistical report are transmitted to a mobile phone APP or a notebook computer and the like, so that a mode that workers need to check and write forms in a visual mode is replaced, the labor intensity is greatly reduced, the labor cost is reduced, and the monitoring efficiency is improved.
(2) The intelligent monitoring system for the wind power blade assembly mold, provided by the invention, has the functions of real-time monitoring of mold parameters, data collection and feedback in the production process, provides enough data support, is beneficial to production technicians to find real reasons of product problems in the production process in time, find process defect reasons, reduce trial and error and quickly find an optimized technical scheme.
(3) The invention only feeds back the heating degree of the mould and the temperature distribution conditions of different positions on the PS surface and the SS surface of the mould in real time, is not only limited to the temperature of the water inlet and the water return of the heater, and provides early warning for the local temperature abnormality of the mould. The invention also provides a real-time online monitoring function for the gap of the die closing seam and the dislocation of the die closing after the die is turned and closed, does not need manual inspection, reduces the labor intensity of workers, reduces the risk of missed inspection and improves the production efficiency of the wind power blade assembly.
(4) The real-time acquisition and automatic monitoring of the die parameters are realized, the manual inspection cost is reduced, and the production efficiency is improved; the alarm can be automatically given according to the set upper and lower limits of the parameters, thereby avoiding the hysteresis of manual recording statistical data and reducing the product loss caused by abnormal parameters through real-time alarm.
(5) Because the blade size is very big, adopt the regional measurement mode of branch, with sensor signal access to the data acquisition module of corresponding region nearby, reduce wiring length and cost.
(6) Data integration is on same monitor platform, can show with cell-phone APP simultaneously at the scene to provide external communication interface, the unified management of data of being convenient for promotes the digital transformation of blade production.
Drawings
Fig. 1 is an overall block diagram of an intelligent monitoring system for a wind power blade assembly mold according to a preferred embodiment of the invention.
FIG. 2 is a schematic view of the installation of a laser displacement sensor for detecting the width of a clamping seam.
FIG. 3 is a schematic view of the installation of a laser displacement sensor for detecting the size of the closed seam dislocation.
Fig. 4 is a schematic view of a monitoring interface (with a graph corresponding to a mold) of monitoring software running on an upper computer.
Fig. 5 is an example of historical trend records and statistics for temperature at a point on the mold.
Detailed Description
For the purpose of better explaining the present invention and to facilitate understanding, the present invention will be described in detail by way of specific embodiments with reference to the accompanying drawings.
Example 1
As shown in fig. 1, the intelligent monitoring system for a wind power blade assembly mold according to a preferred embodiment of the present invention mainly includes three major components, namely, a sensor, a signal acquisition and transmission system, and a control system.
In the embodiment, a wind turbine blade mold is taken as an example for explanation.
The sensor comprises a vacuum degree sensor, a temperature sensor and a laser displacement sensor. The vacuum degree sensors are respectively arranged on the vacuum-pumping pipelines at the rear edge of the upper die and the rear edge of the lower die, and can measure the vacuum degrees of a plurality of positions of the front edge and the rear edge of the die except the vacuum pipelines. The temperature sensor comprises a plurality of thermal resistors which are pre-embedded on the PS surface and the SS surface of the mold, the thermal resistors are uniformly dispersed on the whole surfaces of the PS surface and the SS surface of the mold, and the temperature distribution conditions of different positions on the mold can be measured. The laser displacement sensor comprises a first detector for detecting the width of the die closing seam and a second detector for detecting the axial dislocation degree and the chord-wise dislocation degree of the die closing seam.
The control system comprises an upper computer, an industrial personal computer (control cabinet), a switch, necessary switches, buttons, an alarm and other equipment.
The signal acquisition and transmission system comprises a plurality of data acquisition modules. The upper die and the lower die of the die are divided into a plurality of areas, and each area is provided with a data acquisition module so as to acquire data of all sensors in the area nearby and send the data to an upper computer of a control system. Preferably, as shown in fig. 1, the upper die and the lower die of the die are respectively divided into 2 regions, and 4 regions in total, and each region is provided with a data acquisition module for acquiring data of all sensors in the region where the data acquisition module is located.
The data acquisition module can adopt MODBUS protocol to transmit data through a shielded twisted pair or MODBUS TCP protocol. The upper computer calibrates the data of each sensor according to the measuring range according to the received sensor data;
the algorithm for the data of the vacuum degree sensor and the laser displacement sensor is as follows:
wherein, for the data of the temperature sensor, the algorithm is as follows:
the upper computer runs the monitoring software, and can display the temperature value and the vacuum value measured by the sensors in the upper die and the lower die on the monitoring interface of the monitoring software.
Preferably, as shown in fig. 4, the number of the thermal resistors is 52, the thermal resistors are pre-embedded on the PS surface and the SS surface of the mold during the production and manufacturing of the mold, and 26 thermal resistors are respectively embedded on the PS surface and the SS surface of the mold, and the thermal resistors are uniformly distributed on the whole surfaces of the PS surface and the SS surface of the mold, so as to comprehensively and accurately monitor the temperature of different sites of the mold, and warn that the local temperature is too high.
Preferably, the number of the vacuum degree sensors is 13, wherein 1 of the vacuum degree sensors is arranged on the vacuum-pumping pipeline, and the other 12 vacuum degree sensors are arranged at a vacuum position and a vacuum position of the rear edge of the upper die and the rear edge of the lower die; one vacuum installation of the rear edge of the upper die is 3, the second vacuum installation of the rear edge of the upper die is 3, the first vacuum installation of the rear edge of the lower die is 3, and the second vacuum installation of the rear edge of the lower die is 3, wherein the total number is 12.
When a laser displacement detector is used for detecting the width of the die gap, the installation is as shown in fig. 2. A first reflector 12 is mounted on the edge of one of the upper and lower molds, and a first detector 11 (laser displacement detector) is mounted on the edge of the other. The first detector 11 and the first reflector 12 are both installed at the edge of the glass fiber reinforced plastic shell of the mold, and the distance between the first reflector 12 and the first detector 11 can directly reflect the distance after the PS surface and the SS surface of the mold are closed. The laser beam emitted from the first detector 11 is irradiated onto the first reflecting plate 12, reflected by the first reflecting plate 12 and received by the first detector 11, thereby measuring the width of the parting line between the upper mold and the lower mold. Preferably, the first reflector 12 is mounted on the PS side of the mold and the first detector 11 is mounted on the SS side of the mold. The first reflector 12 can work normally without wiring, and is easy to install, so that the first reflector is preferably installed on the PS surface, and the installation mode can avoid the interference of the wiring when the PS surface is driven to turn by the turning mechanism. As shown in fig. 2, the protective covers 13 are respectively disposed on the outer sides of the first detector 11 and the first reflector 12, the protective cover 13 of the first detector 11 is not combined with the bracket 111 of the first detector 11, and the protective cover 13 of the first reflector 12 is not combined with the first reflector 12, so that a detection error caused by shaking of the protective cover 13 can be avoided.
The first detector and the first reflector at least comprise 10 sets, wherein at least 5 sets are arranged at the front edge of the die, and at least 5 sets are arranged at the rear edge of the die and are used for detecting the width of a die-closing seam; the second detector and the second reflector at least comprise 2 sets of reflectors which are arranged beside the jacking cylinder and used for detecting the axial dislocation degree and the chordwise dislocation degree of the die closing seam.
The mounting method when using the laser displacement detector for detecting the degree of misalignment between the upper and lower molds after mold clamping is shown in fig. 3. The second detector 21 is installed at the side of the jacking cylinder 3, and a second reflector 22 is also installed at the side of the jacking cylinder 3. The second detector 21 and the second reflector 22 are respectively arranged on the upper die and the lower die and used for detecting the dislocation degree of the upper die and the lower die after die assembly, and when the dislocation degree is detected to be higher, a warning is sent out, and the dies are required to be assembled again. Preferably, the second detector 21 is mounted on the PS side of the mold and the second reflector 22 is mounted on the SS side of the mold. The detection principle is as follows: the laser emitting and receiving ends of the second detector 21 are installed corresponding to the second reflector 22 by the bracket 211, the second detector 21 emits laser, the second reflector 22 reflects the laser, the second detector 21 emits laser to receive reflected light, and the axial dislocation degree (distance) and the chordwise dislocation degree (distance) of the matched die seam are measured according to the angle of the reflected light and the time interval from emitting to receiving.
In fig. 1, the data of each sensor collected by the data collection module may be transmitted to the host computer of the control system by a MODBUS tcp communication protocol or a MODBUS protocol. Preferably, when the modbus tcp protocol is adopted for transmission, the data acquisition module and the IP address of the upper computer of the control system are arranged in the same network segment and are connected to the same switch in a wired or wireless manner, the upper computer is set as a client in a reading mode, is connected with the data acquisition module in each area in a cyclic access manner by pointing to different IP addresses, and stores the data in the register area of the switch into different data blocks of the upper computer.
Besides the original data of each sensor acquired by each data acquisition module is sent to the upper computer, the operation, fault signals and other important equipment parameters of a mold heater matched with the wind power blade production, a vacuum pump used for vacuum perfusion, and a hydraulic overturning control cabinet used for overturning a mold (PS surface) are also sent to the upper computer in a wiring or Ethernet communication (or other wireless communication) mode.
Referring to fig. 4, the monitoring interface of the monitoring software operated by the upper computer includes graphs (for simulating the upper die and the lower die of the wind turbine blade die) corresponding to the PS surface and the SS surface of the die, and corresponds to the positions (and the number) of the vacuum degree sensor, the temperature sensor and the laser displacement sensor arranged on the die used in actual production, and a data frame for displaying the detection values of the corresponding position sensors is arranged on the graphs, so that an operator can clearly see the parameter conditions of the die.
In addition, the monitoring software operated by the upper computer can set upper and lower parameter limits according to the process requirements, wherein the upper and lower parameter limits comprise the upper limit of a die closing gap, the upper and lower limits of heating temperature of each stage, the upper and lower limits of vacuum pressure and the like. In the actual production process, the upper computer continuously compares the detection data of each sensor in the production process according to the set upper and lower limits of the parameters and judges whether the detection data exceed the upper and lower limits, once a certain detection data (such as temperature or vacuum degree) of a certain position point on the die exceeds the upper and lower limit range, the upper computer sends an instruction to enable the alarm device to send an alarm to remind field personnel to make a response measure, or on a graph of a direct monitoring interface, a data frame corresponding to the parameter flickers (or changes color, such as becomes striking red) to remind a worker to make a response, and the alarm time, the position of the measurement point and the type of the measurement value are recorded.
Besides the fact that the system can display the parameter conditions of all parts of the mold in the wind power blade production process to an operator in a centralized, comprehensive and timely online mode, the system also utilizes monitoring software to enable all online data obtained in real time to form a historical trend graph, an alarm record and a statistical report according to a time cross axis for on-site query and printing output, and the historical trend graph, the alarm record and the statistical report are transmitted to a mobile phone APP or a notebook computer (shown in a combined mode in figure 1) and used for replacing a mode that workers need to check and write forms in a visual mode, labor intensity is greatly reduced, labor cost is reduced, and monitoring efficiency is improved. For example, an example of temperature history trend records and statistics is shown in FIG. 5.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. An intelligent monitoring system for a wind power blade assembly mold is characterized by comprising a sensor, a signal acquisition and transmission system and a control system;
the wind power blade assembly mold is a wind power blade mold, a blade root mold, a web plate mold or a blade main beam mold;
the control system comprises an upper computer;
the sensor comprises a vacuum degree sensor, a temperature sensor and a laser displacement sensor; the laser displacement sensors are used for detecting the width of the die closing seam, the axial dislocation degree and the chord direction dislocation degree of the die closing seam; the vacuum degree sensors comprise a plurality of vacuum degree sensors which are respectively arranged on the vacuum-pumping pipelines at the rear edges of the upper die and the lower die; the temperature sensor comprises a plurality of thermal resistors which are pre-embedded on the surfaces of the upper die and the lower die, and the thermal resistors are uniformly distributed on the whole surfaces of the upper die and the lower die;
the signal acquisition and transmission system comprises a data acquisition module; the upper die and the lower die of the die are divided into a plurality of areas, each area is provided with a data acquisition module, and the data acquisition modules in each area are used for acquiring data of all sensors in the area and sending the data to an upper computer of the control system;
the upper computer calibrates the data of each sensor according to the measuring range according to the received sensor data;
the algorithm for the data of the vacuum degree sensor and the laser displacement sensor is as follows:
pmax and Pmin respectively correspond to the upper and lower limits of the measuring range of the sensor, and in is the original data acquired by the data acquisition module from the corresponding sensor;
wherein, for the data of the temperature sensor, the algorithm is as follows:
the upper computer runs the monitoring software, and can display the temperature value and the vacuum value measured by the sensors in the upper die and the lower die on the monitoring interface of the monitoring software.
2. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the laser displacement sensor comprises a first detector for detecting the width of the mold closing seam, a first reflector is mounted on the edge of one of the upper mold and the lower mold, a first detector is mounted on the edge of the other of the upper mold and the lower mold, laser emitted by the first detector irradiates on the first reflector, is reflected by the first reflector and received by the first detector, and the width of the mold closing seam between the upper mold and the lower mold is sensed by the first detector.
3. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the laser displacement sensor comprises a second detector for detecting the axial dislocation degree and the chord-wise dislocation degree of the matched die seam; the second detector is arranged beside the jacking cylinder, and a second reflector is also arranged beside the jacking cylinder; the second detector is arranged on the PS surface of the mould, and the second reflector is arranged on the SS surface of the mould; the laser emitting and receiving end of the second detector corresponds to the second reflector; the axial dislocation degree and the chordwise dislocation degree of the mold closing seam can be detected and detected by the second detector and the second reflector.
4. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the number of the thermal resistors is at least 52, the thermal resistors are pre-embedded on a PS surface and an SS surface of the mold during production and manufacturing of the mold, at least 26 thermal resistors are respectively arranged on the PS surface and the SS surface of the mold, and the thermal resistors are uniformly distributed on the whole surfaces of the PS surface and the SS surface of the mold and used for monitoring the temperature of different sites of the mold.
5. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the number of the vacuum degree sensors is at least 13, one of the vacuum degree sensors is installed on the vacuum-pumping pipeline, and the other vacuum degree sensors are installed at a vacuum position and a second vacuum position on the rear edge of the upper mold and the rear edge of the lower mold; at least 3 vacuum installations are arranged on one side of the rear edge of the upper die, at least 3 vacuum installations are arranged on the other side of the rear edge of the upper die, at least 3 vacuum installations are arranged on one side of the rear edge of the lower die, and at least 3 vacuum installations are arranged on the other side of the rear edge of the lower die.
6. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the first detector and the first reflector comprise at least 10 sets, at least 5 sets of the first detector and the first reflector are arranged at the front edge of the mold, and at least 5 sets of the first detector and the first reflector are arranged at the rear edge of the mold and are used for detecting the width of a mold closing seam; the second detector and the second reflector at least comprise 2 sets of reflectors which are arranged beside the jacking cylinder and used for detecting the axial dislocation degree and the chordwise dislocation degree of the die closing seam.
7. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the upper mold and the lower mold of the mold are respectively divided into 2 regions, total 4 regions, and each region is provided with a data acquisition module for acquiring data of all sensors in the region where the data acquisition module is located.
8. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the data collected by the data collection module is transmitted by using MODBUS TCP protocol; the IP addresses of the data acquisition module and an upper computer of the control system are arranged in the same network segment and are connected to the same switch in a wired or wireless mode, the upper computer is used as a client side and is set to be in a reading mode, the upper computer is connected with the data acquisition module of each area in a cyclic access mode by pointing to different IP addresses, and data in the register area of the switch are stored in different data blocks of the upper computer.
9. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the monitoring interface of the upper computer comprises a graph corresponding to a PS surface and an SS surface of the mold, and a data frame for displaying detection values of corresponding position sensors is arranged on the graph corresponding to positions of a vacuum degree sensor, a temperature sensor and a laser displacement sensor arranged on the mold.
10. The intelligent monitoring system for the wind power blade assembly mold according to claim 1, wherein the monitoring software sets upper and lower parameter limits according to process requirements, the upper and lower parameter limits include upper limit of a die joint, upper and lower limits of heating temperature of each stage, and upper and lower limits of vacuum pressure, the upper computer judges detection data of each sensor in a production process according to the set upper and lower parameter limits, and when certain detection data exceeds the upper and lower limit ranges, a corresponding data frame on a graph of a monitoring interface flashes at a position to remind a worker and record alarm time, a measurement point position and a measurement value type.
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| CN115495454A (en) * | 2022-09-30 | 2022-12-20 | 中信戴卡股份有限公司 | Aluminum wheel casting forming technological process characterization method |
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