CN219888203U - Real-time monitoring and fault diagnosis system for gearbox of wind driven generator - Google Patents

Abstract

The utility model discloses a real-time monitoring and fault diagnosis system of a wind driven generator gear box, which comprises a plurality of vibration sensors and a rotating speed sensor which are respectively arranged on a gear box shell, a torque sensor arranged at a driving end of the gear box, a lubricating oil dust monitoring module and a liquid oil quality sensor which are respectively arranged on a liquid oil circuit, wherein the vibration sensors are arranged on the gear box shell; the control box comprises a core module, a data acquisition module and a wireless communication module; the utility model monitors the quantity of particles in the liquid oil in real time, judges the abrasion condition of each part in the gear box according to the dielectric constant of the oil and the quantity of scraps in the oil, monitors the torque at the output end of the gear box, and when the excessive torque of the gear box is monitored, the torque diagnosis module sends out an early warning signal or an alarm signal, thereby avoiding damaging equipment due to the excessive torque.

Description

Real-time monitoring and fault diagnosis system for gearbox of wind driven generator

Technical Field

The utility model belongs to the field of fault diagnosis, and particularly relates to a real-time monitoring and fault diagnosis system for a gearbox of a wind driven generator.

Background

In the prior art, a common method for detecting faults of a gear box is mainly judged manually according to modes of vibration, noise, oil temperature, temperature and the like generated in the running process of the gear.

On the other hand, the cable shield layer is a composite material composed of carbon black, a crosslinking agent, and the like, and contains a large number of functional groups. In the actual operation process of the cable, the shielding layer not only plays a role of a uniform electric field, but also serves as a bridge between the insulating layer and the conductor, so that the aging state of the shielding layer is particularly important to evaluate.

On the other hand, the existing patent name is a gear box fault signal acquisition device based on an acoustic sensor array, the application number is CN201720186371.2, the acoustic sensor array is adopted in the patent, noise interference can be effectively reduced, accuracy of acquiring the acoustic signals is provided, the problem that other interference such as noise is inevitably encountered in the acquisition process of the acoustic signals in the prior art, the difficulty of detecting faults is increased is solved, but the fault of the gear box is judged only from the sound extraction angle, an early warning function does not exist for the fault of the gear box, and an identification function does not exist for the fault with small sound such as oil leakage of the gear box.

The prior patent name is a wind power generation gear box fault diagnosis simulation experiment table, the application number is CN201620494098.5, the patent provides a method similar to the working principle of a wind power generator, the working state of the wind power generator can be more accurately simulated, so that the fault condition of the wind power generator can be accurately judged, the time is saved, the efficiency is improved, but the patent only identifies faults through a vibration sensor and is not comprehensive.

In summary, in the prior art, the fault identification has a missing judgment condition, and the fault cannot be early warned.

Disclosure of Invention

In order to solve the problems, the utility model aims to provide a gearbox real-time monitoring and fault diagnosis system capable of accurately identifying faults of a gearbox of a wind driven generator and timely sending out early warning signals.

In order to achieve the above object, the technical scheme of the present utility model is as follows:

the utility model discloses a comprehensive real-time analysis early warning monitoring system, which comprises a plurality of wind power generation devices and generators respectively arranged on the wind power generation devices, wherein a gear box is connected to the generators, a liquid-oil loop is connected to the gear box, and a rotating speed sensor for monitoring the rotating speed of a motor is arranged on the generators; the control box comprises a core module, a data acquisition module and a wireless communication module; the core module is connected with the data acquisition module and the wireless communication module respectively, and the data acquisition module is connected with a plurality of vibration sensors, torque sensors, lubricating oil scraps monitoring modules, rotating speed sensors and liquid oil quality sensors respectively.

Further, the wind power generation device further comprises a plurality of temperature sensors arranged in the generator and an environment temperature and humidity sensor arranged on the outer surface of the wind power generation device, wherein the data acquisition module is respectively connected with the plurality of temperature sensors and the environment temperature and humidity sensor, and the temperature sensors comprise motor winding temperature sensors and motor bearing temperature sensors.

Further, the vibration sensor comprises a radial vibration sensor for monitoring radial vibration of the gear and an axial vibration sensor for monitoring axial vibration of the gear box.

Further, a touch display screen for providing a human-computer interaction interface is arranged on the control box, and the touch display screen is connected with the core module.

Further, the liquid-oil loop comprises an oil liquid pipeline, an oil liquid circulating pump arranged on the oil liquid pipeline, a filter arranged in the oil liquid pipeline and used for preventing oil liquid pollution, and a liquid oil tank communicated with the liquid oil pipeline.

Further, the wireless communication system also comprises an upper computer, wherein the upper computer is connected with the core module through the wireless communication module.

Further, a state monitoring module for monitoring and recording the real-time state of the gear box and the real-time state of the generator and a fault diagnosis module for judging the gear box fault and the generator fault according to the identification result of the state monitoring module are arranged in the upper computer.

Further, the state monitoring module comprises a temperature monitoring module, a vibration monitoring module, a metal skimming monitoring module of a rotating speed monitoring module, a liquid oil quality monitoring module and a torque monitoring module.

Further, the fault diagnosis module comprises a temperature diagnosis module, a vibration diagnosis module, a rotation speed diagnosis module, a metal skimming diagnosis module, a liquid oil quality diagnosis module and a torque diagnosis module.

Further, the device also comprises an oil storage disc which is arranged at the bottom of the gearbox, the generator and the oil liquid loop and used for receiving oil leakage of equipment, wherein an oil immersion alarm is arranged at the lowest point of the disc surface of the oil storage disc, and the oil immersion alarm is in communication connection with the data acquisition module.

After the scheme is adopted, the following beneficial effects are realized:

the utility model monitors the quantity of particles in the liquid oil in real time, judges the abrasion condition of each part in the gear box according to the dielectric constant of the oil and the quantity of scraps in the oil, monitors the torque at the output end of the gear box, and when the excessive torque of the gear box is monitored, the torque diagnosis module sends out an early warning signal or an alarm signal, thereby avoiding damaging equipment due to the excessive torque.

The utility model sets the early warning parameters before the alarm, makes early warning before the fault occurs, and deals with the fault in advance.

The utility model respectively identifies the gear machine faults from a plurality of angles such as particles, vibration, torque and the like of oil, so that the gear machine faults are more accurately identified.

When oil leakage occurs in any one of the liquid-oil loop, the gear box and the generator, oil drips to the oil storage disc, the oil immersion alarm is immersed, the oil immersion alarm sends an alarm signal to the core module through the data acquisition module, the touch display screen reads data in the CPU of the Siemens smart-200, an alarm is sent out at the display interface, alarm sound is sent out, and meanwhile, the upper computer acquires the alarm signal through the wireless transmission module.

Drawings

Fig. 1 is a schematic diagram of a hardware connection structure of a comprehensive real-time analysis early warning monitoring system provided in embodiment 1 of the present utility model;

fig. 2 is a schematic diagram of a connection structure between an upper computer and each wind power generation device of the comprehensive real-time analysis early warning and monitoring system provided in embodiment 1 of the present utility model;

fig. 3 is a schematic diagram of a connection structure between an upper computer and each wind power generation device of the comprehensive real-time analysis early warning and monitoring system provided in embodiment 2 of the present utility model;

FIG. 4 is a schematic diagram of the upper computer structure in the present utility model.

Detailed Description

The following is a further detailed description of the embodiments:

example 1

As shown in fig. 1 to 4: the comprehensive real-time analysis early warning monitoring system comprises a plurality of wind power generation devices and generators respectively arranged on the wind power generation devices, wherein a gear box is connected to the generators, a liquid oil loop is connected to the gear box, and a rotating speed sensor for monitoring the rotating speed of a motor is arranged on the generators; the control box comprises a core module, a data acquisition module and a wireless communication module; the core module is connected with the data acquisition module and the wireless communication module respectively, and the data acquisition module is connected with a plurality of vibration sensors, torque sensors, lubricating oil scraps monitoring modules, rotating speed sensors and liquid oil quality sensors respectively.

It should be noted that the oil quality sensor is mainly used for measuring the dielectric constant of oil, and indirectly reflects the aging condition of oil, when the more metal particles are in the oil, which are caused by the aggravation of gear abrasion in the gear box, the larger the value of the dielectric constant is, the more obvious the polarization phenomenon is, and the larger the value of the dielectric constant is. Similarly, the lubricating oil residue monitoring module is also used for monitoring the content of metal particles in the gear box and also used for monitoring the content of nonmetallic particles. The device can monitor the quantity of particles with different diameters, and judge the abrasion condition of the gear box according to different change trends of particles with different diameters in different abrasion stages in the gear box.

More specifically, when installation lubricating oil bits end monitoring module and liquid oil quality sensor, in order to guarantee that the fluid that two equipment were monitored is as far as possible unanimous with the fluid in the gear box, its lubricating oil bits end monitoring module and liquid oil quality sensor are as close as possible to the gear box when the installation, and also are as close as possible between two equipment of lubricating oil bits end monitoring module and liquid oil quality sensor.

More specifically, in this embodiment, the core module adopts a CPU module of siemens smart-200, the data acquisition module also adopts a siemens series expansion module collocated with the core module, including a digital quantity input module, a digital quantity output module, an analog quantity input module, an analog quantity output module, an expansion communication module, the expansion communication module includes an RS485 expansion module and an RS232 expansion module, and the CPU module of siemens smart-200 also supports the modbus tcp protocol with its RJ45 interface; in this embodiment, the vibration sensor, the torque sensor, the lubricating oil chip end monitoring module and the liquid oil quality sensor are all in communication connection with the CPU module of siemens smart-200 through the RS485 expansion module, and care should be taken. And various temperature sensors and outdoor temperature sensors are in communication connection with the CPU module of the Siemens smart-200 through an analog input module.

The system further comprises a plurality of temperature sensors arranged in the generator and an environment temperature and humidity sensor arranged on the outer surface of the wind power generation device, wherein the data acquisition module is respectively connected with the plurality of temperature sensors and the environment temperature and humidity sensor, and the temperature sensors comprise motor winding temperature sensors and motor bearing temperature sensors.

Wherein the vibration sensor comprises a radial vibration sensor for monitoring radial vibration of the gear and an axial vibration sensor for monitoring axial vibration of the gearbox.

In actual use, the radial vibration sensor and the axial vibration sensor are identical in model and specification, and are different in installation direction, wherein the radial vibration sensor is installed along the radial direction parallel to the driving end of the gear box, and the axial vibration sensor is installed along the axial direction parallel to the driving end of the gear box;

the control box is provided with a touch display screen for providing a human-computer interaction interface, and the touch display screen is connected with the core module. The touch display screen is used for displaying real-time operation parameters of the on-site generator and the gearbox and controlling equipment such as the on-site generator, the gearbox and the like.

The liquid-oil loop comprises an oil liquid pipeline, an oil liquid circulating pump arranged on the oil liquid pipeline and a filter arranged in the oil liquid pipeline and used for preventing oil liquid pollution.

The wireless communication system also comprises an upper computer, wherein the upper computer is connected with the core module through the wireless communication module.

The wireless communication module is one of a 4G/5G communication module, a GPS communication module and a lora wireless communication module.

More specifically, the utility model can be arranged in a monitoring station and is in communication connection with a plurality of wind power generation devices, so as to intensively monitor the faults of the gearbox and the generator in the plurality of wind power generation devices.

Example 2

The upper computer can also be arranged in the wind power generation device and used for monitoring the fault of a gear box and the fault of a generator in the wind power generation device. The upper computer in each wind power generation device is in communication connection with the upper computers in other wind power generation devices through the wireless transmission module, so that a decentralised network connection structure is formed, and communication among other wind power generation devices is not affected even if a wind power generation device at a certain place fails. Meanwhile, the wind power generation device has the capability of independent operation, and even if the station is disconnected from other stations, the device can independently process field faults.

Example 3

The embodiment is a further supplement to embodiment 1, and specifically, the device further comprises an oil storage disc which is respectively arranged at the bottoms of the gearbox, the generator and the oil liquid loop and used for receiving oil leakage of equipment, wherein an oil immersion alarm is arranged at the lowest point of the disc surface of the oil storage disc, and the oil immersion alarm is in communication connection with the data acquisition module. The oil immersed alarm also establishes communication with the CPU module of Siemens smart-200 through the RS485 expansion module.

When oil leakage occurs in any one of the liquid-oil loop, the gear box and the generator, oil drips to the oil storage disc, the oil immersion alarm is immersed, the oil immersion alarm sends an alarm signal to the core module through the data acquisition module, the touch display screen reads data in the CPU of the Siemens smart-200, an alarm is sent out at the display interface, alarm sound is sent out, and meanwhile, the upper computer acquires the alarm signal through the wireless transmission module.

Example 4

The upper computer is provided with a state monitoring module for monitoring and recording the real-time state of the gear box and the real-time state of the generator respectively, and a fault diagnosis module for judging the gear box fault and the generator fault respectively according to the identification result of the state monitoring module.

The state monitoring module comprises a temperature monitoring module, a vibration monitoring module, a rotating speed monitoring module, a metal dust monitoring module, a liquid oil quality monitoring module and a torque monitoring module.

The fault diagnosis module comprises a temperature diagnosis module, a vibration diagnosis module, a rotation speed diagnosis module, a metal skimming diagnosis module, a liquid oil quality diagnosis module and a torque diagnosis module.

More specifically, a temperature monitoring module in the upper computer monitors real-time data of an environment temperature and humidity sensor, a motor winding temperature sensor and a motor bearing temperature sensor, and stores and generates temperature and humidity trend curves of the sensors; the temperature diagnosis module presets the upper and lower alarm limits, the upper and lower alarm limits and the upper change limit of each temperature sensor or each temperature and humidity sensor, wherein the range of the upper alarm limit and the lower alarm limit comprises the upper alarm limit and the lower alarm limit, when the real-time data of the temperature or the humidity is not between the upper alarm limit and the lower alarm limit but is between the upper alarm limit and the lower alarm limit, the temperature diagnosis module sends out an early alarm signal, and when the real-time data of the temperature or the humidity is not between the upper alarm limit and the lower alarm limit, the temperature diagnosis module sends out an alarm signal; when the absolute value of the change rate of the real-time data of the temperature or the humidity in unit time exceeds the upper change limit, the data mutation, the sensor abnormality or the equipment abnormality are indicated, and an alarm signal is sent.

Similarly, a vibration monitoring module in the upper computer monitors real-time data of a radial vibration sensor for monitoring radial vibration of the gear and an axial vibration sensor for monitoring axial vibration of the gear box, and stores and generates a vibration trend curve of each sensor; the vibration diagnosis module presets the upper and lower alarm limits, the upper and lower alarm limits and the upper change limit of each vibration sensor, wherein the range of the upper and lower alarm limits comprises the upper and lower alarm limit range, when the real-time vibration data is not between the upper and lower alarm limits but is between the upper and lower alarm limits, the vibration diagnosis module sends out an early warning signal, and when the real-time vibration data is not between the upper and lower alarm limits, the vibration diagnosis module sends out an alarm signal; when the absolute value of the change rate of the real-time data of the vibration exceeds the upper change limit, the data mutation, the sensor abnormality or the equipment abnormality are indicated, and an alarm signal is sent.

The rotating speed monitoring module is used for monitoring the rotating speed real-time data of the current generator; the rotation speed diagnosis module is provided with a rotation speed alarm upper limit and a rotation speed early warning upper limit, wherein the value of the rotation speed alarm upper limit is larger than the rotation speed early warning upper limit, when the rotation speed exceeds the rotation speed early warning upper limit, the rotation speed diagnosis module sends out a rotation speed early warning signal, and when the rotation speed exceeds the rotation speed alarm upper limit, the rotation speed diagnosis module sends out a rotation speed alarm signal.

Similarly, the torque monitoring module is used for monitoring real-time data of torque at the driving end of the current gear box, the torque diagnosis module is provided with a torque alarm upper limit and a torque early warning upper limit, wherein the value of the torque alarm upper limit is larger than the torque early warning upper limit, when the torque exceeds the torque early warning upper limit, the torque diagnosis module sends out a torque early warning signal, and when the torque exceeds the torque alarm upper limit, the torque diagnosis module sends out a torque alarm signal.

The metal skimming monitoring module is used for monitoring metal particles in the oil liquid, storing the data and generating a particle increment curve; the liquid oil quality monitoring module is used for monitoring the dielectric constant of oil, storing the data and generating a dielectric constant change curve, the metal skimming diagnosis module and the liquid oil quality diagnosis module are matched, the metal skimming diagnosis module is provided with an alarm upper limit of the number of particles with various diameters, and the alarm upper limit of the number of particles with various diameters is mainly provided with an alarm upper limit of the number of particles with 200-300 mu m and an alarm upper limit of the number of particles; when the particle number of 200-300 mu m exceeds the particle number early warning upper limit but is lower than the particle number warning upper limit, the liquid oil quality diagnosis module sets a dielectric constant change upper limit, the metal skimming diagnosis module sends out an alarm signal, and when the particle number of 200-300 mu m exceeds the particle number warning upper limit and the dielectric constant of oil is greater than the dielectric constant change upper limit, the metal skimming diagnosis module sends out an alarm signal.

The utility model monitors the quantity of particles in the liquid oil in real time, judges the abrasion condition of each part in the gear box according to the dielectric constant of the oil and the quantity of scraps in the oil, monitors the torque at the output end of the gear box, and when the excessive torque of the gear box is monitored, the torque diagnosis module sends out an early warning signal or an alarm signal, thereby avoiding damaging equipment due to the excessive torque.

The utility model sets the early warning parameters before the alarm, makes early warning before the fault occurs, and deals with the fault in advance.

The utility model respectively identifies the gear machine faults from a plurality of angles such as particles, vibration, torque and the like of oil, so that the gear machine faults are more accurately identified.

It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

The foregoing is merely an embodiment of the present utility model, and a specific structure and characteristics of common knowledge in the art, which are well known in the scheme, are not described herein, so that a person of ordinary skill in the art knows all the prior art in the application date or before the priority date, can know all the prior art in the field, and has the capability of applying the conventional experimental means before the date, and a person of ordinary skill in the art can complete and implement the present embodiment in combination with his own capability in the light of the present utility model, and some typical known structures or known methods should not be an obstacle for a person of ordinary skill in the art to implement the present utility model. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present utility model, and these should also be considered as the scope of the present utility model, which does not affect the effect of the implementation of the present utility model and the utility of the patent. The protection scope of the present utility model is subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.

Claims (10)

1. The real-time monitoring and fault diagnosis system for the gearbox of the wind driven generator comprises a plurality of wind driven generators and generators respectively arranged on the wind driven generators, wherein the generators are connected with a gearbox, a liquid-oil loop is connected to the gearbox, and a rotating speed sensor for monitoring the rotating speed of a motor is arranged on the generators. The control box comprises a core module, a data acquisition module and a wireless communication module; the core module is connected with the data acquisition module and the wireless communication module respectively, and the data acquisition module is connected with a plurality of vibration sensors, torque sensors, lubricating oil scraps monitoring modules, rotating speed sensors and liquid oil quality sensors respectively.

2. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the wind power generation device comprises a wind power generation device, a data acquisition module, a generator and a temperature sensor, and is characterized by further comprising a plurality of temperature sensors arranged in the generator and an environment temperature and humidity sensor arranged on the outer surface of the wind power generation device, wherein the data acquisition module is respectively connected with the plurality of temperature sensors and the environment temperature and humidity sensor, and the temperature sensors comprise motor winding temperature sensors and motor bearing temperature sensors.

3. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the vibration sensor comprises a radial vibration sensor for monitoring radial vibration of the gear and an axial vibration sensor for monitoring axial vibration of the gear box.

4. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the control box is provided with a touch display screen for providing a human-computer interaction interface, and the touch display screen is connected with the core module.

5. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the liquid-oil loop comprises an oil liquid pipeline, an oil liquid circulating pump arranged on the oil liquid pipeline, a filter arranged in the oil liquid pipeline and used for preventing oil liquid pollution, and a liquid oil tank communicated with the oil liquid pipeline.

6. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the wireless communication system also comprises an upper computer, wherein the upper computer is connected with the core module through the wireless communication module.

7. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 6, wherein: the upper computer is provided with a state monitoring module for monitoring and recording the real-time state of the gear box and the real-time state of the generator respectively, and a fault diagnosis module for judging the gear box fault and the generator fault respectively according to the identification result of the state monitoring module.

8. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 7, wherein: the state monitoring module comprises a temperature monitoring module, a vibration monitoring module, a rotating speed monitoring module, a metal dust monitoring module, a liquid oil quality monitoring module and a torque monitoring module.

9. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 7, wherein: the fault diagnosis module comprises a temperature diagnosis module, a vibration diagnosis module, a rotation speed diagnosis module, a metal skimming diagnosis module, a liquid oil quality diagnosis module and a torque diagnosis module.

10. The system for real-time monitoring and fault diagnosis of a wind turbine gearbox of claim 1, wherein: the oil storage disc is arranged at the lowest point of the disc surface of the oil storage disc, and the oil immersion alarm is in communication connection with the data acquisition module.