CN114963973A - Bolt crack detection device and method based on fiber bragg grating array sensing film - Google Patents
Bolt crack detection device and method based on fiber bragg grating array sensing film Download PDFInfo
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Abstract
The invention discloses a bolt crack detection device based on a fiber grating array sensing film, which comprises a film sensor, the film sensor comprises a film and a plurality of fiber grating string sensors, the fiber grating string sensors form a fiber grating sensing array network, the fiber grating sensing array network is embedded into the film, the film sensor is formed after high-temperature curing, simultaneously discloses a detection method of the detection device, the prepared film sensor is tightly adhered to the surface of the wind power bolt screw, and is connected to a multi-channel fiber bragg grating demodulator, then the feedback spectrum demodulation signal is sent to a wireless router of a fan main machine cabin through a wireless transmission module, and the spectrum demodulation signal is wirelessly transmitted to a wind field control center finally, so that the fatigue trend of the wind power bolt is monitored and predicted in real time.
Description
Technical Field
The invention relates to the technical field of health monitoring of bolt structures of large-scale wind turbine generators, in particular to a bolt crack detection device and method based on a fiber bragg grating array sensing film.
Background
With the rapid development of the wind power industry, a plurality of problems are brought, various mechanical faults and accidents of the wind power generation set in the operation process gradually enter a high-occurrence period, and the operation and maintenance pressure is obviously increased. The bolt connection is one of the most main connection modes in the wind turbine generator, and key structural components of the wind turbine generator, such as wind turbine blades, a main shaft hub, a tower drum and the like, are almost all connected by high-strength and high-torque bolts. Due to the time-varying characteristic of the wind speed, the wind turbine generator runs under the alternating load working condition, and the fatigue crack damage is easily caused by the alternating stress action borne by the wind turbine bolts along with the increase of the running time. If cracks are not found in time in the process of the regular inspection, serious consequences can be caused, and even serious safety accidents and economic losses can be caused. In order to ensure the safe operation of the wind turbine, fatigue cracks on the bolts must be detected as early as possible in order to be replaced in a timely manner. However, early fatigue cracks in wind power bolts can only be manifested when and only when the wind turbine is not stopped. However, most of the existing wind power bolt detection adopts manual regular detection in a fan shutdown state. On one hand, the shutdown of the fan inevitably affects the total power generation amount and the power generation efficiency of the wind field, so that economic loss is caused; on the other hand, the manual regular inspection is high in cost and high in potential safety hazard, and more importantly, early cracks are difficult to find in time. Therefore, how to detect the cracks of the wind power bolts on line under the non-stop state of the wind turbine generator is an important technical problem in the field of damage detection of the wind power bolts, and a widely recognized detection means and an industry standard are not yet available.
At present, common wind power bolt detection technologies include a circuit loop technology, a piezoelectric technology, a vibration-stress composite sensing technology, an ultrasonic technology, a fiber bragg grating technology and the like. The former techniques mainly focus on the diagnosis and monitoring of mechanical faults such as wind power bolt looseness, axial force and deformation, and monitoring signals are easily influenced by an electromagnetic field. Although the ultrasonic technology can be used for detecting the cracks of the bolts, the ultrasonic technology is mainly used for quickly detecting common bolts, manual operation is still needed for detection, and detection signals are easily subjected to electromagnetic interference. Therefore, the ultrasonic technology is difficult to realize the online detection of the wind power bolt cracks. The fiber grating sensing technology has been widely applied in the field of health monitoring of wind power bolt structures at home and abroad by virtue of the advantages of corrosion resistance, high sensitivity, electromagnetic interference resistance and the like, and mainly relates to monitoring and early warning of loosening, deformation, pretightening force and the like of the wind power bolt, for example, the fiber grating sensing technology is used for detecting strain and stress data of the bolt in real time to realize real-time assessment of bolt deformation and loosening.
However, the existing wind power bolt monitoring application based on the fiber grating sensing technology inevitably needs grooving or trepanning processing on the bolt, the overall structural strength of the bolt is damaged to a certain extent, and a single fiber grating sensor can only sense the bolt strain change in the grating area and cannot sense the bolt strain change in the non-grating area in time. Due to the randomness of the positions and the time abruptness of the fatigue cracks of the wind power bolts, the fatigue trend of the bolts is difficult to master in real time only by a single fiber grating sensor, and the quantitative detection of the fatigue cracks of the bolts cannot be realized.
Disclosure of Invention
Aiming at the defects of the existing wind power bolt fiber bragg grating detection technology, the invention provides a bolt crack detection device and method based on a fiber bragg grating array sensing film, which can be used for greatly improving the crack detection precision while identifying the crack of the bolt.
In order to achieve the purpose, the invention provides the following technical scheme: the bolt crack detection device based on the fiber bragg grating array sensing film comprises a film sensor, wherein the film sensor comprises a film and a plurality of fiber bragg grating string sensors, a plurality of the fiber bragg grating string sensors form a fiber bragg grating sensing array network, the fiber bragg grating sensing array network is embedded into the film, and the film sensor is formed after high-temperature curing.
Preferably, the fiber grating sensing array area is coated, peeled and fixed in a shallow bottom metal mold, and the film is formed by pouring optical polymer resin into the shallow bottom metal mold, and uniformly scraping the optical polymer resin by using a scraper, so that the optical polymer resin covers the periphery of the fiber grating sensing array and is integrally formed through high-temperature curing.
Preferably, the number and the pitch of the gratings included in each fiber grating string sensor are equal.
The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film comprises the following steps of:
s1, adopting a high-strength adhesive to closely adhere the prepared film sensor to the surface of a screw rod of a wind power bolt, sleeving a bolt gasket into the bolt, and manufacturing a wedge-shaped gasket notch on the bolt gasket to lead out a plurality of optical fiber bundles in the film sensor;
s2, connecting the tail ends of the optical fiber bundles led out from the bolt gasket with a plurality of channels of a multi-channel fiber bragg grating demodulator through the optical fiber bundle jumper heads;
s3, because the grating positions in the film sensor are fixed, different grating positions correspond to different positions on the screw rod of the bolt, when a crack appears on the screw rod of the bolt, the fiber bragg grating reflection spectrum peak wavelength drift amount corresponding to the crack area is obviously higher than the fiber bragg grating reflection spectrum peak wavelength drift amount corresponding to the crack area, different spectrum signals are formed by feedback in the multi-channel fiber bragg grating demodulator, are sent to the router of the fan main machine cabin through the wireless transmission module, and are received by the fan server through the network cable;
and S4, finally, wirelessly transmitting the spectrum signal to a wind field control center through the Internet of things technology, and monitoring and predicting the fatigue trend of the wind power bolt in real time.
Preferably, in S3, the number of cracks is determined according to the number of fiber grating reflection spectra having high peak wavelength drift in different channels of the multi-channel fiber grating demodulator, and the position of the crack is identified according to the grating position in the fiber grating array corresponding to the fiber grating reflection spectrum position having high peak wavelength drift.
Preferably, the types of cracks detected include axial crack propagation, circumferential crack propagation, and oblique crack propagation.
Preferably, when the crack axially extends along the screw of the bolt and covers a plurality of grating positions in the same optical fiber, the length of the axial crack extension is determined according to the adjacent grating spacing in the optical fiber grating array corresponding to the peak wavelength change of the reflection spectrum of the optical fiber grating in the same channel of the multi-channel optical fiber grating demodulator.
Preferably, when the crack circumferentially extends to cover a plurality of grating positions at the same latitude in different optical fibers along the screw of the bolt, the length of the circumferential crack extension is determined according to the array pitch of the grating at the same latitude in different optical fibers corresponding to the spectral peak wavelength change of the adjacent channel grating of the multi-channel fiber grating demodulator.
Preferably, when the crack obliquely expands along the screw of the bolt to cover a plurality of grating positions in different optical fibers, the length and the direction of the oblique crack expansion are determined according to the grating array distances with different dimensions in different optical fibers corresponding to the spectral peak wavelength change of the adjacent channel grating of the multi-channel fiber grating demodulator.
Compared with the prior art, the invention has the beneficial effects that:
1. the method can implement conventional monitoring items such as wind power bolt looseness, deformation and early warning force, and more importantly can detect the fatigue crack damage of the bolt on line.
2. According to the invention, the flexible fiber grating array film sensor can be directly adhered to the surface of the wind power bolt, and the fiber grating array film sensor does not need to be arranged on the surface of the wind power bolt in a groove or hole, so that the online nondestructive detection of the wind power bolt is really realized.
3. The invention can realize real-time quantitative detection of crack parameters such as the position, the length, the direction and the like of the multi-zone cracks of the bolt by using the fiber grating array sensing technology.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention.
In the drawings:
FIG. 1 is a schematic structural diagram of an online detection device for cracks of a wind power bolt of the invention;
FIG. 2 is a schematic structural diagram of a flexible fiber grating array film sensor according to the present invention;
FIG. 3 is a schematic structural view of a wind power bolt of the present invention;
FIG. 4 is a schematic view of the construction of the bolt washer of the present invention;
FIG. 5 is a flow chart of a wind power bolt crack parameter detection method according to the present invention;
FIG. 6 is a structural schematic of axial crack propagation of the present invention;
FIG. 7 is a structural schematic of the circumferential crack propagation of the present invention;
FIG. 8 is a schematic structural view of the oblique crack propagation of the present invention;
the reference numbers in the figures: 1. a bolt; 2. an optical fiber; 3. a grating; 4. a film; 5. a fiber bundle jumper; 6. a gasket gap; 7. a gasket; 8. a thin film sensor; 9. an adhesive layer; 10. a multi-channel fiber grating demodulator; 11. a wireless transmission module; 12. a router; 13. a network cable; 14. a fan server; 15. wind field control center.
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
As shown in fig. 1-4, the device for detecting a bolt crack based on a fiber grating array sensing film comprises a film sensor 8, wherein the film sensor 8 comprises a film 4 and a plurality of fiber grating string sensors, a plurality of gratings 3 are etched on each optical fiber 2 to form the fiber grating string sensors, the plurality of fiber grating string sensors form the fiber grating sensing array network, the number and the intervals of the gratings 3 contained in each fiber grating string sensor are equal, the fiber grating sensing array network is embedded or implanted into the film 4 to form a flexible film sensor 8, wherein the film 4 is formed by pouring optical polymer resin into a shallow metal mold and uniformly scraping the optical polymer resin by using a scraper, so that the optical polymer resin covers the periphery of the fiber grating sensing array network, and integrally formed through high-temperature curing.
As shown in fig. 1 and fig. 5 to 8, the detection method of the bolt crack detection device based on the fiber bragg grating array sensing film comprises the following steps:
s1, adopting a high-strength adhesive to tightly bond the prepared film sensor 8 on the surface of a screw rod of the wind power bolt 1, sleeving the bolt gasket 7 into the bolt 1, and manufacturing a wedge-shaped gasket 7 notch 6 on the bolt gasket 7 to lead out a plurality of optical fiber 2 bundles in the film sensor 8;
s2, connecting the ends of the optical fibers 2 led out from the bolt gasket 7 with a plurality of channels of a multi-channel fiber grating demodulator 10 through the optical fiber bundle jumper 5;
s3, since the positions of the gratings 3 in the film sensor 8 are fixed, different grating 3 positions correspond to different positions on the screw of the bolt 1, when a crack occurs on the screw of the bolt 1, the shift of the spectrum peak wavelength of the grating 3 corresponding to the crack region will be significantly higher than the shift of the spectrum peak wavelength of the grating 3 corresponding to the crack-free region, the number of cracks is determined according to the number of the fiber grating reflection spectra having high shift of the peak wavelength in different channels of the multi-channel fiber grating demodulator 10, and the position of the crack is identified according to the position of the grating 3 in the fiber grating array corresponding to the fiber grating reflection spectrum having high shift of the peak wavelength;
when the crack is expanded along the axial direction of the screw of the bolt 1 and covers a plurality of grating 3 positions in the same optical fiber 2, the length of the expansion of the axial crack can be determined according to the distance between adjacent gratings 3 in the optical fiber grating array corresponding to the spectral peak wavelength change of the grating 3 in the same channel of the multi-channel optical fiber grating demodulator 10;
when the crack circumferentially expands along the screw of the bolt 1 and covers a plurality of gratings 3 at the same latitude in different optical fibers 2, the circumferential crack expansion length can be determined according to the array spacing of the gratings 3 at the same latitude in different optical fibers 2 corresponding to the spectral peak wavelength change of the adjacent channel gratings 3 of the multi-channel fiber grating demodulator 10;
when the crack obliquely expands along the screw of the bolt 1 and covers a plurality of gratings 3 in different optical fibers 2, the length and the direction of the oblique crack expansion can be determined according to the array spacing of the gratings 3 with different dimensions in the different optical fibers 2 corresponding to the spectral peak wavelength change of the gratings 3 of the adjacent channels of the multi-channel fiber grating demodulator 10;
then, different spectrum signals are fed back and formed in the multi-channel fiber bragg grating demodulator 10, are sent to a wireless router 12 of a fan main engine bin through a wireless transmission module 11, and are received by a fan server 14 through a network cable 13;
and S4, finally, wirelessly transmitting the spectrum signal to a wind field control center 15 through the Internet of things technology, and monitoring and predicting the fatigue trend of the wind power bolt 1 in real time.
The specific operation is as follows:
firstly, preparing a film sensor 8, and tensioning and fixing a plurality of optical fibers 2 with local area coating layers stripped in a shallow rectangular metal mold with a hole opened in the middle in advance, wherein the number and the intervals of gratings 3 contained in each fiber grating string sensor are equal; and then, pouring elastic optical polymer resin into the shallow metal mold, uniformly spreading the elastic optical polymer resin by using a scraper, and curing at high temperature to form a film 4, thereby finally forming the flexible film sensor 8 embedded in the fiber grating sensing array network.
Secondly, a thin film sensor 8 is pasted, a high-strength adhesive is adopted to form an adhesive layer 9, the prepared thin film sensor 8 is tightly adhered to the surface of a screw rod of the wind power bolt 1, the bolt gasket 7 is sleeved in the bolt 1, and a wedge-shaped gasket gap 6 is formed in the bolt gasket 7 so as to lead out a plurality of optical fiber 2 bundles in the thin film sensor 8.
And finally, connecting the thin film sensor 8 to a multi-channel fiber grating demodulator 10, connecting the tail ends of a plurality of optical fibers 2 led out from the bolt gasket 7 with a plurality of channels of the multi-channel fiber grating demodulator 10 through a fiber bundle jumper 5, sending spectrum demodulation signals fed back in the multi-channel fiber grating demodulator 10 to a wireless router 12 of a fan main engine bin through a wireless transmission module 11, receiving the spectrum demodulation signals by a fan server 14 through a network cable 13, and finally wirelessly transmitting the spectrum demodulation signals to a wind field control center 15 through the internet of things technology to monitor and predict the fatigue trend of the wind power bolt 1 in real time.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (9)
1. Bolt crack detection device based on fiber grating array sensing film, its characterized in that: the film sensor comprises a film sensor and a plurality of fiber grating string sensors, wherein the fiber grating string sensors form a fiber grating sensing array network, the fiber grating sensing array network is embedded into the film, and the film sensor is formed after high-temperature curing.
2. The fiber bragg grating array sensing film based bolt crack detection device according to claim 1, wherein: the fiber grating sensing array area is coated, stripped and fixed in a shallow bottom metal mold, the optical polymer resin is poured into the shallow bottom metal mold, the optical polymer resin is evenly scraped by a scraper, the periphery of the fiber grating sensing array is covered with the optical polymer resin, and the fiber grating sensing array area is integrally formed through high-temperature curing.
3. The fiber bragg grating array sensing film based bolt crack detection device according to claim 2, wherein: the number and the spacing of the gratings contained in each fiber grating string sensor are equal.
4. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film is characterized by comprising the following steps of:
s1, adopting a high-strength adhesive to tightly bond the prepared film sensor on the surface of a screw rod of the wind power bolt, sleeving a bolt gasket into the bolt, and manufacturing wedge-shaped gasket notches on the bolt gasket to lead out a plurality of optical fiber bundles in the film sensor;
s2, connecting the tail ends of the optical fiber bundles led out from the bolt gasket with a plurality of channels of a multi-channel fiber bragg grating demodulator through the optical fiber bundle jumper heads;
s3, because the grating positions in the film sensor are fixed, different grating positions correspond to different positions on the screw rod of the bolt, when a crack appears on the screw rod of the bolt, the fiber bragg grating reflection spectrum peak wavelength drift amount corresponding to the crack area is higher than the fiber bragg grating reflection spectrum peak wavelength drift amount corresponding to the crack area, different spectrum signals are formed by feedback in the multi-channel fiber bragg grating demodulator, sent to the router of the fan main machine cabin through the wireless transmission module and received by the fan server through the network cable;
and S4, finally, wirelessly transmitting the spectrum signal to a wind field control center through the Internet of things technology, and monitoring and predicting the fatigue trend of the wind power bolt in real time.
5. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film according to claim 4, wherein the detection method comprises the following steps: in S3, the number of cracks is determined according to the number of the fiber grating reflection spectra having high peak wavelength drift in different channels of the multi-channel fiber grating demodulator, and the position of the crack is identified according to the grating position in the fiber grating array corresponding to the fiber grating reflection spectra position having high peak wavelength drift.
6. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film according to claim 5, wherein the detection method comprises the following steps: the types of cracks detected include axial crack propagation, circumferential crack propagation, and oblique crack propagation.
7. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film according to claim 6, wherein the detection method comprises the following steps: when the crack axially expands along the screw of the bolt to cover a plurality of grating positions in the same optical fiber, the length of the axial crack expansion is determined according to the adjacent grating space in the optical fiber grating array corresponding to the peak wavelength change of the reflection spectrum of the optical fiber grating in the same channel of the multi-channel optical fiber grating demodulator.
8. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film according to claim 6, wherein the detection method comprises the following steps: when the crack circumferentially extends to a plurality of grating positions at the same latitude in different optical fibers along the screw of the bolt, the length of the circumferential crack extension is determined according to the array spacing of the grating at the same latitude in different optical fibers corresponding to the spectrum peak wavelength change of the adjacent channel grating of the multi-channel fiber grating demodulator.
9. The detection method of the bolt crack detection device based on the fiber bragg grating array sensing film according to claim 6, wherein the detection method comprises the following steps: when the crack obliquely expands along the screw of the bolt to cover a plurality of grating positions in different optical fibers, the length and the direction of the oblique crack expansion are determined according to the grating array distances with different dimensions in different optical fibers corresponding to the spectral peak wavelength change of the adjacent channel grating of the multi-channel fiber grating demodulator.
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Inventor after: Xie Weiguo Inventor after: Zhang Xuejun Inventor after: Zhou Peng Inventor after: Gu Guoqing Inventor after: Chen Liyun Inventor after: Cao Yang Inventor after: Wang Dongdong Inventor before: Xie Weiguo Inventor before: Zhang Xuejun Inventor before: Zhou Peng Inventor before: Gu Guoqing Inventor before: Chen Liyun Inventor before: Cao Yang Inventor before: Wang Dongdong |