Intelligent monitoring method for speed regulator

Abstract

The invention relates to the technical field of water and electricity, and discloses an intelligent monitoring method for a speed regulator, which comprises the following steps: arranging a signal acquisition assembly and an execution element, and forming a continuous curve according to time based on signal data acquired by the signal acquisition assembly; wherein the signal data comprises oil pressure, flow, oil temperature, oil level, oil quality, noise, smell, opening degree, current and voltage; executing fault diagnosis early warning according to the continuous curve and / or video data acquired by the infrared camera; and based on a set starting condition, according to the signal data acquired in real time, when the set starting condition is reached, starting an emergency disposal scheme, and executing emergency disposal operation. Safety and reliability can be further improved, operation management and overhaul and maintenance work are intelligent as much as possible, and therefore long-term stable operation of the hydropower station is guaranteed.

Description

Technical Field

[0001] The present invention relates to the field of hydropower technology, and in particular to an intelligent monitoring method for a speed regulator. Background Art

[0002] Since its development, small hydropower has become a clean, carbon-free, and environmentally friendly renewable energy source, an indispensable energy source for the power industry. As a key piece of equipment for small hydropower, speed regulators have undergone significant technological advancements, evolving from fully manual speed regulators to electromechanical and hydraulic speed regulators to microcomputer-based speed regulators. With the continuous advancement of AI technology, speed regulators require further upgrades to ensure safer, more comprehensive, and more intelligent functionality.

[0003] As a key device for regulating water flow, the speed governor's accurate and timely control of water volume is essential for ensuring normal production and power generation. Closing the guide vanes too slowly during an emergency shutdown can result in excessive speed and damage to the equipment. Closing the speed governor too quickly can cause excessive water hammer in the pressure pipes, leading to major safety incidents such as pipe bursts. In special circumstances, when the system is disconnected, all units shut down, and plant power is lost, the speed governor's ability to maintain sufficient oil pressure to restart and restore plant power is a key factor in ensuring the safety of small hydropower plants. Furthermore, when many small hydropower plants shed load at remote points in the system, the speed governor fails to adjust its opening in time to reduce the speed because the collected grid frequency and machine frequency are equal. Emergency adjustments are not initiated until the speed becomes too high, potentially leading to runaway accidents. Misoperation during inspection and maintenance can also lead to safety incidents.

[0004] Most current speed regulators are microcomputer-based, and while their technology has improved, they lack reliability and safety due to various issues with their software and hardware, posing significant safety risks. They are generally not yet capable of "unmanned operation." Furthermore, a shortage of skilled personnel in power plants makes operation and maintenance difficult. Even if "unmanned operation" or "reduced staffing" is implemented, safety risks remain significant. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent monitoring method for a speed regulator to further improve safety and reliability, and to make its operation management, inspection and maintenance as intelligent as possible, thereby ensuring the long-term stable operation of a hydropower station.

[0006] In order to achieve the above purpose, the technical solutions adopted are as follows:

[0007] A speed regulator intelligent monitoring method, the method comprising:

[0008] Signal acquisition components were deployed as follows: an oil pressure sensor and flow meter were installed on the governor's oil filling pipe, oil supply pipe, and oil return pipe; an opening sensor and noise meter were installed in the water turbine room, and an infrared camera was installed on top of the governor's oil tank; an infrared thermometer, noise meter, and electronic nose were installed outside the oil pump motor; a switching current transformer and a voltage transformer were installed in the main electrical circuit of the oil pump motor; and a switching current transformer was installed in the secondary circuit of the current transformer at the generator outlet and the secondary circuit of the current transformer on the grid line.

[0009] Based on the signal data collected by the signal acquisition component, a continuous curve is formed according to time; wherein the signal data includes at least one of oil pressure, flow, oil temperature, oil level, oil quality, noise, odor, opening, current, and voltage;

[0010] Performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera;

[0011] Based on the set start-up conditions and the real-time collected signal data, the emergency response plan is activated when the set start-up conditions are met.

[0012] Furthermore, performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes:

[0013] When the oil pressure drops to the first oil pressure threshold and oil flows out of the oil filling pipe, an emergency oil pressure warning is executed;

[0014] When the oil pressure rises to the second oil pressure threshold, the oil pump motor has working current and oil flows out of the oil filling pipe, the oil pressure high warning is executed;

[0015] When the oil pressure drops to the third oil pressure threshold and the main pump motor has no working current, or when the oil pressure drops to the fourth oil pressure threshold and the standby pump motor has no working current, or when the oil pressure rises to the fifth oil pressure threshold and the oil pump motor has working current, or the oil pump motor has working current, the governor oil pressure does not rise and there is no oil flowing in the oil supply pipe, or the oil pump motor has working current and there is no oil flowing in the oil supply pipe, and the average oil pressure rising speed is slower than before and exceeds the set threshold, or the oil pump current is larger than the normal working current or there is a phase loss, an abnormal oil injection warning is executed;

[0016] When the oil pump motor operating current lasts longer than the set time, the flow meter measures the oil volume entering the oil storage tank and increases beyond the set threshold, and the oil level in the tank decreases, the capsule abnormality warning is executed;

[0017] When there is no oil flowing out of the oil supply pipe, the oil pressure drops and / or the oil level in the fuel tank drops gradually, and the oil supply of the oil supply pipe is greater than the oil return of the oil return pipe in multiple time periods, a pipeline oil leakage warning is executed;

[0018] According to the ambient air temperature and oil temperature change curve, when the ambient temperature remains unchanged or drops, the oil temperature in the fuel tank rises. When the oil temperature is greater than 40°C, an abnormal oil temperature warning is executed;

[0019] When the governor receives a command and there is no oil flow in the oil supply pipe and the oil return pipe and / or the valve does not have an action command and there is oil flow in the oil supply pipe and the oil return pipe, a valve failure warning is executed;

[0020] When any signal acquisition component interrupts uploading data or continuously generates abnormal data, an input information abnormality warning is executed;

[0021] When the guide vane opening keeps changing, the valve keeps moving, and there is oil flow in both the oil supply pipe and the oil return pipe, an opening twitch warning is executed;

[0022] When the ammeter, voltmeter, and power meter swing periodically and the swing amplitude exceeds the set amplitude, a system oscillation warning is executed;

[0023] When the unit is running under load and the guide vane opening gradually decreases without adjustment, a slip load warning is executed;

[0024] When the remote controller sends a governor operation command, there is no oil flow in the oil supply pipe and return pipe, and the guide vane opening does not change, a remote control failure warning is executed;

[0025] When the speed governor is automatically running in the no-load state and the frequency of the running unit cannot be stabilized within the set frequency threshold range, the no-load unit frequency warning is executed;

[0026] When an abnormal odor is detected that exceeds the standard, an odor abnormality warning is executed;

[0027] When the sound type or volume exceeds the standard, an abnormal sound warning is issued.

[0028] Furthermore, performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes:

[0029] Use the following methods to determine the failure of the oil pressure device capsule:

[0030] Based on theoretical calculation and actual measurement, the function curves of the oil filling volume and capsule pressure and the oil filling volume and time of the two capsules are obtained, and the total oil filling volume V0 of the two capsules from the start-up oil pressure to the rated oil pressure is calculated;

[0031] During actual operation, each time the pressure oil increases from the starting pressure to the rated oil pressure, the actual oil filling volume V1 is calculated using the flow rate measured by the flow meter and the corresponding time, and compared with the total oil filling volume V0 during debugging. If the difference exceeds the normal error and the oil filling time increases compared to the previous value, a capsule abnormality warning is issued;

[0032] The actual oil filling volume of the faulty capsule is obtained by subtracting the oil filling volume V0 / 2 of one or two capsules during the original debugging from the actual oil filling volume. The residual pressure value of the faulty capsule is calculated by comparing the oil filling volume obtained during debugging with the function curve of the capsule pressure.

[0033] Based on the oil filling volume and time function curve obtained from debugging, the two pumps are started to fill oil separately, and the pump with shorter filling time is determined. The capsule close to the pump with shorter filling time is identified as the faulty capsule.

[0034] Furthermore, before debugging based on theoretical calculations and actual measurements, the method for determining a fault in the oil pressure device capsule also includes:

[0035] When filling nitrogen into two capsules of the same model, the pressure is equal, and the volumes of two pressure oil tanks of the same model are set to be equal and directly connected;

[0036] When the oil pump is set to fill the oil tank with pressurized oil, the pressures on the two capsules are equal, the volumes of the nitrogen in the capsules contracted by pressure are equal, and the volumes of pressurized oil filled in the two pressure oil tanks are also equal.

[0037] Furthermore, performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes:

[0038] Based on the real-time monitoring of the three-phase current of the grid-connected outgoing line, when it is detected that the three-phase current suddenly and quickly drops to zero, and the rate of change and starting point both exceed the set value, the unit frequency and voltage rise rapidly, and the generator output circuit breaker is in the closed state, a remote load shedding alarm is immediately issued.

[0039] Furthermore, when the pipeline oil leakage warning is issued, the method further includes: determining the oil leakage amount based on the quantity difference time function.

[0040] Furthermore, determining the oil leakage amount based on the quantity difference time function includes:

[0041] The oil leakage of the oil pipeline per unit time is calculated by the difference between the equivalent oil supply volume of the oil supply pipeline to the relay and the oil return volume of the return pipeline per unit time;

[0042] When the oil leakage in the oil pipeline exceeds the normal metering error per unit time, an oil leakage warning is immediately issued. The amount of oil leaked is calculated based on the leakage start time and the amount difference time function.

[0043] Furthermore, performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes:

[0044] Under various power supply voltages, multiple sets of current-time curves are generated and stored based on the current changes during the process of the oil pressure rising from the starting pressure to the rated oil pressure after the oil pump is started.

[0045] By detecting the power supply voltage, starting current, normal working current and duration, the actual current-time curve is obtained;

[0046] The actual current-time curve is compared with the stored current-time curve. When it is detected that the actual starting current and working current are significantly higher than the stored curve current for multiple times, or the current is missing and lasts for more than 2 seconds, or a short circuit current occurs, or the current exceeds the stall current and lasts for more than 1 second, an oil pump fault warning is immediately issued and the oil pump is controlled to stop running.

[0047] Furthermore, based on the set start-up conditions and according to the real-time collected signal data, when the set start-up conditions are met, the emergency response plan is activated, including:

[0048] When the speed governor executes a fast oil use command, and the speed governor oil pressure is lower than the sixth oil pressure threshold and the working pump motor has no working current, the standby oil pump is started in advance to pump oil, and stops pumping oil after reaching the set pressure;

[0049] When the power supply to the plant is lost during an accident shutdown and the oil pressure drops to the starting pressure, the emergency power supply is immediately used to pump oil;

[0050] When the ammeter, voltmeter, and power meter oscillate periodically, reduce the active load and then fix the opening;

[0051] When the three-phase currents of the outgoing current transformers are simultaneously zero, the duration of simultaneous zero is more than 10 seconds, the current is not less than 10% of the rated current 3 seconds before the three-phase currents are simultaneously zero, and the unit frequency and voltage rise rapidly after the three-phase currents are simultaneously zero, a guide vane adjustment instruction is sent to the speed governor to limit the unit frequency to the set frequency threshold in advance;

[0052] When the oil pressure exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump;

[0053] When it is detected that the oil pump motor current reaches the locked-rotor current or above, there is no oil flowing into or out of the oil filling pipe, and the oil filling pipe pressure does not rise, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump;

[0054] After an appropriate delay is applied to detect an external short circuit, if the short circuit current has not disappeared, the active power will be reduced to no-load, and an external short circuit and switch refusal to trip alarm will be issued.

[0055] The beneficial effects of the present invention are:

[0056] This system monitors the operation and maintenance process to determine its correctness, effectively preventing misoperation and improving the intelligence level of the speed regulator. It not only reduces labor intensity, improves work efficiency, and enhances the technical level of the speed regulator, but also improves equipment safety performance through transformation, greatly reduces safety risks, and effectively prevents safety accidents.

[0057] It is mainly reflected in the following six aspects:

[0058] 1. More comprehensive operation monitoring

[0059] The current monitoring of small hydropower mainly monitors the oil pressure of the speed regulator and the guide vane opening, but this system also monitors the oil level, oil temperature, oil quality, sound, odor, oil flow, motor current and duration, video, etc., and the monitoring content is more comprehensive.

[0060] 2. More timely information feedback

[0061] Because the system's various measuring components are independently installed and utilize real-time monitoring, feedback times can be reduced to less than one second, making it much faster and more timely than current manual monitoring methods. Monitoring data analysis and calculations provide advanced warnings of equipment failures, allowing personnel to identify problems before they occur and, through timely intervention or resolution, prevent equipment failures or accidents from occurring.

[0062] 3. More accurate analysis and judgment

[0063] By independently installing multiple high-precision measuring devices and verifying multiple detection methods, this system accurately determines the current state of the speed regulator, effectively avoiding data errors caused by component failures or situations where communication interruptions to a measuring component prevent information from being determined. For example, the system can indicate whether the oil pump is pumping oil through four completely different methods: the motor's main circuit current, the flow rate in the oil filling pipe, the oil level change in the oil tank, and the sound of the oil pump. This effectively prevents misjudgments caused by a failure in a specific measurement circuit. Currently, during normal operation of small hydropower plants, staff cannot determine capsule anomalies. This system can not only determine capsule anomalies during normal operation, but also determine which capsule is abnormal and calculate the current residual pressure value of the faulty capsule.

[0064] 4. Information interaction is more convenient

[0065] Through voice interaction equipment, human-computer voice dialogue and direct notification to mobile phone text messages can be achieved, allowing staff to make various choices or operations more quickly and conveniently, thereby improving work efficiency.

[0066] 5. Higher safety and reliability

[0067] During normal operation, the system utilizes advanced fault warning and emergency response features to enable early intervention and eliminate potential causes before an accident occurs. Transparent safety shields are installed at all vulnerable piping connections, minimizing the impact on routine inspections and preventing direct injury from accidental pressurized oil injection. Furthermore, the addition of a maintenance safety lock adds a reliable safety measure to the "Two Tickets, Three Systems" system, effectively preventing accidents caused by misoperation during maintenance and ensuring the inherent safety of the speed regulator.

[0068] 6. Higher work efficiency

[0069] By using artificial intelligence in this system to replace the work of professionals, multiple tasks such as operation monitoring, patrol inspection, fault diagnosis, and emergency response can be carried out simultaneously. Not only is the work content extensive, but it is also completed quickly, so the work efficiency is very high. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] Figure 1 The figure is a flow chart of a method for intelligent monitoring of a speed regulator according to an embodiment of the present invention.

[0071] Figure 2 The process of performing fault diagnosis and early warning according to an embodiment of the present invention is shown. Figure 1 .

[0072] Figure 3 The process of performing fault diagnosis and early warning according to an embodiment of the present invention is shown. Figure 2 .

[0073] Figure 4 A flowchart of performing fault diagnosis and early warning according to an embodiment of the present invention is shown.

[0074] Figure 5 The figure shows the overall structure of an intelligent speed regulator according to an embodiment of the present invention.

[0075] Figure 6 A side view of an intelligent speed regulator according to an embodiment of the present invention is shown.

[0076] Figure 7 A front view of an intelligent speed regulator according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0077] The following describes the embodiments of the present invention through specific examples. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. The details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other unless they conflict.

[0078] The specific implementation of the present invention is further described in detail below with reference to the accompanying drawings and examples.

[0079] An embodiment of the present invention provides a method for intelligently monitoring a speed regulator. Based on the actual conditions of the speed regulator during actual production and operation at a hydropower station, a speed regulator intelligent monitoring system (hereinafter referred to as this system) is constructed using various measuring elements, video equipment, intelligent monitors, actuators, and related connecting pipes or wires. Based on the operating principles of the various components or parts of the speed regulator, various operating parameters of the speed regulator are determined through comprehensive analysis of multiple factors and comparison of full-cycle data curves. Intelligent devices are used to replace on-duty personnel to complete all or part of the tasks including operation monitoring, patrol inspections, regular meter reading, fault self-tests, maintenance operation guidance, accident or fault advance warnings, intelligent control, and emergency response. Furthermore, artificial intelligence is used to enable voice interaction between humans and devices.

[0080] like Figure 1 FIG. 1 is a flow chart of a method for intelligently monitoring a speed regulator according to an embodiment of the present invention. The method comprises the following steps:

[0081] S100. Arrange the signal acquisition components in the following manner: install an oil pressure sensor and a flow meter on the governor oil filling pipe, the oil supply pipe, and the oil return pipe, respectively; install an opening sensor and a noise meter in the water machine room, and install an infrared camera on the top of the governor oil tank; install an infrared thermometer, a noise meter, and an electronic nose outside the oil pump motor; install an opening and closing current transformer and a voltage transformer in the main electrical circuit of the oil pump motor; install an opening and closing current transformer in the secondary circuit of the current transformer at the generator outlet and the secondary circuit of the current transformer on the grid line.

[0082] S200. Based on the signal data collected by the signal acquisition component, a continuous curve is formed according to time; wherein the signal data includes oil pressure, flow, oil temperature, oil level, oil quality, noise, odor, opening, current, and voltage.

[0083] It should be noted that the above-mentioned signal data such as oil pressure, flow, oil temperature, oil level, oil quality, noise, odor, opening, current, voltage, etc. are collected by various signal acquisition components respectively. The signal data collected by each signal acquisition component forms a continuous curve according to time, that is, signal time curves of signal data collected by multiple groups of different signal acquisition components are obtained. In subsequent steps, these signal time curves will be used to perform automated fault diagnosis and early warning and as the basis for initiating emergency response plans.

[0084] In some embodiments, the speed governor intelligent monitoring method further includes installing maintenance locks on the speed governor's main oil supply valve and pressure relief valve, and connecting position information and electromagnetic command transmission lines to the speed governor intelligent monitor to provide reliable locks for speed governor maintenance safety. Transparent protective covers are installed at each high-pressure pipeline joint to prevent high-pressure oil from flying around and injuring people in the event of an accident.

[0085] S300: Perform fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera.

[0086] For example, the intelligent controller communicates with the power plant's existing microcomputer monitoring system to obtain unit operating parameters, the transmission and reception of speed control oil valve actuation instructions, and other information. In this application scenario, the speed governor monitor sets normal ranges for the operating data of relevant information under various conditions according to the actual power plant operating procedures. First, it uses real-time monitored operating parameters combined with odor, sound, etc. to detect whether the speed governor is abnormal. Then, a camera is used to monitor key parts of the speed governor in real time, and image comparison is used to determine whether the speed governor's appearance is normal. If the comprehensive judgment confirms that it is normal, the operating indicator lights up green; otherwise, the operating indicator lights up red, thereby realizing intelligent speed governor operation monitoring. The speed governor monitor uploads key operating data to the microcomputer monitoring host computer in real time. Because the host computer automatically saves the data on the hour, intelligent operation meter reading is realized.

[0087] In some embodiments, cameras can be used for regular inspections to fully check the appearance of the speed regulator and read relevant meter parameters. They can check for oil leaks, foreign objects, and any remaining foreign objects. In addition, they can combine temperature, noise, odor, and other information to comprehensively determine whether the speed regulator is operating normally, making inspections intelligent.

[0088] In some embodiments, as Figure 2 and Figure 3 As shown, fault diagnosis and early warning are performed according to the continuous curve and / or the video data collected by the infrared camera, including the following steps S201 to S215.

[0089] S201: When the oil pressure drops to a first oil pressure threshold and oil flows out of the oil filling pipe, an emergency oil pressure warning is executed;

[0090] S202: When the oil pressure rises to a second oil pressure threshold, the oil pump motor has an operating current and oil flows out of the oil filling pipe, a high oil pressure warning is executed;

[0091] S203: When the oil pressure drops to the third oil pressure threshold and the main pump motor has no operating current, or when the oil pressure drops to the fourth oil pressure threshold and the standby pump motor has no operating current, or when the oil pressure rises to the fifth oil pressure threshold and the oil pump motor has an operating current, or when the oil pump motor has an operating current, the governor oil pressure does not rise, and there is no oil flowing in the oil supply pipe, or when the oil pump motor has an operating current and there is no oil flowing in the oil supply pipe, and the average oil pressure rising speed slows down and exceeds the set threshold, or when the oil pump current is greater than the normal operating current or there is a phase loss, a fueling abnormality warning is executed;

[0092] S204: When the oil pump motor operating current lasts for more than a set time, the flow meter measures the oil volume entering the oil storage tank and increases by more than a set threshold, and the oil level in the tank decreases, a capsule abnormality warning is executed;

[0093] S205: When there is no oil flowing out of the oil supply pipe, the oil pressure drops and / or the oil level in the fuel tank drops gradually, and the oil supply volume of the oil supply pipe is greater than the oil return volume of the oil return pipe during multiple time periods, a pipeline oil leakage warning is executed;

[0094] S206: Based on the ambient air temperature and oil temperature change curve, when the ambient temperature remains unchanged or decreases while the oil temperature in the fuel tank increases, and when the oil temperature is greater than 40°C, an oil temperature abnormality warning is executed;

[0095] S207: When the speed governor receives an instruction and there is no oil flow in the oil supply pipe and the oil return pipe and / or there is no valve actuation instruction and there is oil flow in the oil supply pipe and the oil return pipe, a valve failure warning is executed;

[0096] S208. When any signal acquisition component interrupts uploading data or continuously generates abnormal data, execute an input information abnormality warning;

[0097] S209: When the guide vane opening keeps changing, the valve keeps moving, and there is oil flow in both the oil supply pipe and the oil return pipe, an opening twitch warning is executed;

[0098] S210: When the ammeter, voltmeter, and power meter periodically swing and the swing amplitude exceeds the set amplitude, a system oscillation warning is executed;

[0099] S211: When the unit is running under load and the guide vane opening gradually decreases without adjustment, a slip load warning is executed;

[0100] S212: When it is detected that the remote controller sends a speed governor operation command, there is no oil flow in the oil supply pipe and the return pipe, and the guide vane opening does not change, a remote control failure warning is executed;

[0101] S213: When the speed governor is automatically running in the no-load state and the frequency of the generator set cannot be stabilized within the set frequency threshold range, a no-load frequency warning is executed;

[0102] S214: When an abnormal odor exceeding the standard is detected, an abnormal odor warning is executed;

[0103] S215: When it is detected that the sound type or volume exceeds the standard, execute a sound abnormality warning.

[0104] It should be noted that the above steps S201 to S215 can be implemented by configuring an intelligent speed regulator monitor based on the existing speed regulator. Steps S201 to S215 are not executed sequentially, but rather in parallel. That is, each time the measured signal data (continuous curve or video data) is received, steps S201 to S215 are judged simultaneously, thereby improving data processing efficiency.

[0105] After the fault diagnosis and warning of steps S201 to S215 are completed, different operations will be performed according to the type of warning determined. For example, a display can be added to display the warning content and handling suggestions when the fault diagnosis and warning are executed. The specific method is shown in Table 1 below.

[0106] Table 1 Fault diagnosis and warning items

[0107]

[0108]

[0109]

[0110] Therefore, the present invention can monitor the operating status of the speed regulator from multiple aspects by real-time monitoring of various operating parameters such as oil level, oil temperature, oil quality, sound, odor, oil flow, motor current and duration, video, etc. during normal operation, and use preset programs to compare the time function curves of various parameters and the upper and lower limit values to timely discover abnormal conditions and pre-discover possible accidents or failures in the future, so that the staff have enough time to eliminate hidden dangers and eliminate accidents in the bud, so that the maintenance work can be advanced from "accident maintenance" to "condition maintenance".

[0111] In some embodiments, accurate diagnosis of oil pressure device capsule failure can be achieved based on the signal data collected in step S200. Specifically, due to the small volume and limited cost of the capsules in the small hydropower oil pressure device, there is no pressure monitoring for the capsules in the oil pressure device, and the capsules are always sealed in the oil tank during operation and cannot be observed. They can only be discovered after a major problem occurs and affects the operation. After this transformation, the pressure of the two identical capsules will be equal when they are filled with nitrogen, and the volumes of the two identical oil tanks will be set to be equal and directly connected. When the oil pump fills the oil tank with pressurized oil, the pressure on the two oil tank capsules is equal, and the volume of the nitrogen in the capsules that is compressed and contracted is also equal. Therefore, the volume of pressurized oil filled in the two pressure oil tanks is also equal. After this system modification, a flow meter on the oil filling line allows for debugging during installation and commissioning using a combination of theoretical calculations and field measurements. A single capsule measures the oil filling volume (the total oil volume is calculated by integrating the flow rate and time at each time period) and oil pressure curves as the pump fills the oil at different pressures, from a starting pressure of 13.5 MPa to the rated pressure of 16 MPa. This generates oil filling volume-pressure and oil filling volume-time function curves. The two capsules are then filled with nitrogen to the rated pressure and equalized. Separate oil pumps are then used to pump oil from 13.5 MPa to the rated pressure of 16 MPa. Separate oil filling volume-pressure and oil filling volume-time function curves are generated for each pump. The total oil filling volume (V0) for the two pressure tanks from 13.5 MPa to the rated pressure of 16 MPa is calculated, as well as the required oil filling volume (V0 / 2) for each pressure tank from 13.5 MPa to the rated pressure of 16 MPa.

[0112] During actual operation, each time the pressure oil pressure rises from the starting pressure of 13.5 MPa to the rated pressure of 16 MPa, the actual oil filling volume V1 is calculated using the flow rate measured by the flowmeter and the corresponding time. When compared with the initial commissioning oil filling volume V0, if the difference exceeds a normal tolerance (e.g., 10%) or the filling time increases significantly, a capsule abnormality warning is issued. The actual oil filling volume of the faulty capsule tank is calculated by subtracting the initial commissioning oil filling volume V0 / 2 from the actual filling volume. This is then verified using an existing capsule filling volume-pressure function curve to reversely calculate the residual pressure of the faulty capsule. Furthermore, due to the varying lengths of the oil supply paths during startup of different pumps, the longer the oil flow path, the longer the time it takes to fill the faulty capsule tank. Combined with the oil filling volume-time function curve measured during commissioning, the startup of the two pumps is compared. The pump with the shorter oil filling time indicates that the faulty capsule is closer to that pump, thus confirming the faulty capsule. In short, this method can not only detect capsule failure problems that were previously undetectable in a timely manner, but also determine which capsule is faulty and what the current pressure is in MPa, and can accurately diagnose capsule failures in oil pressure devices.

[0113] In some embodiments, during the fault diagnosis and early warning process, remote load shedding is determined by setting the current rate of change to zero. Specifically, in a small hydropower plant, when a sudden load shedding occurs, the three-phase current rapidly drops to zero, and the unit frequency and voltage rapidly increase, with a significant rate of change. During normal load increases and decreases, the current does not drop to zero; even if it does, it decreases slowly, typically less than 10% of the rated value before tripping. This system monitors the three-phase current of the grid-connected outgoing line in real time. When it detects that the three-phase current suddenly drops to zero, the rate of change and the onset point both exceed set values, the unit frequency and voltage rapidly increase, and the generator output circuit breaker is closed, a remote load shedding alarm is immediately issued.

[0114] In some embodiments, the amount of oil leakage is determined by an equivalent quantity difference-time function. Specifically, since flow meters are installed in the oil filling pipeline, the oil supply pipeline, and the oil return pipeline, the amount of oil leakage in the oil pipeline per unit time can be calculated by the difference between the equivalent oil supply volume of the oil supply pipeline to the relay per unit time (first, the volume of the unit volume of oil under each pressure is measured by experimental method, and the volume after losing all external artificial pressure is compared with the volume under the original pressure to obtain the volume coefficient, and finally a pressure-coefficient curve is formed. Then, the pressure-coefficient curve is used to convert the measured oil supply volume under each pressure into the pressure-free oil volume, which is the equivalent oil volume) and the return oil volume of the return oil pipe. When the calculated oil leakage volume exceeds the normal metering error, a pipeline oil leakage warning is immediately issued. According to the time when the leakage started, the amount of oil leaked is calculated by multiplying the oil volume difference per unit time by the time length.

[0115] In some embodiments, a current method is used to diagnose oil pump faults. Specifically, by adding a current transformer and a voltage transformer to the main circuit of the oil pump motor, the changes in current and voltage during the normal startup and oil filling process of the oil pump are monitored in real time. At various power supply voltages, the current changes during the process of the oil pressure rising from 13.5MPa to 16MPa after the oil pump is started are recorded to form and store multiple sets of current-time curves. By detecting the power supply voltage, starting current, and the magnitude and duration of the normal operating current, the actual current-time curve is obtained and compared with the stored current-time curve. When it is detected that the actual starting current and operating current are significantly higher than the stored curve current multiple times; when the current is missing a phase and lasts for 2 seconds; when a short circuit current occurs; when the current exceeds the stall current and lasts for 1 second, etc., an oil pump fault warning is immediately issued and the oil pump is automatically stopped.

[0116] S400: Based on the set starting conditions and according to the real-time collected signal data, when the set starting conditions are met, the emergency response plan is started.

[0117] In this embodiment, compared with the traditional speed regulator, an emergency response function is added. When an emergency is detected, in order to ensure safety, the system automatically executes and quickly completes multiple emergency operation instructions, eliminates safety hazards and prevents the occurrence of safety accidents, and realizes the intelligence of emergency response work.

[0118] In some embodiments, as Figure 4 As shown, based on the real-time collected signal data, when the set start conditions are met, the emergency response plan is activated, including:

[0119] S401: When the speed regulator executes a rapid oil use instruction, and the speed regulator oil pressure is lower than the sixth oil pressure threshold and the working pump motor has no working current, the standby oil pump is started in advance to pump oil, and stops pumping oil after reaching the set pressure;

[0120] S402: When the power supply to the plant is lost during an accident shutdown and the oil pressure drops to the starting pressure, immediately start the emergency power supply to pump oil;

[0121] S403. When the ammeter, voltmeter, and power meter periodically swing, reduce the active load and then fix the opening;

[0122] S404: When the three-phase currents of the outgoing current transformers are simultaneously zero, the duration of simultaneous zero is more than 10 seconds, the current is not less than 10% of the rated current 3 seconds before the three-phase currents are simultaneously zero, and the unit frequency and voltage increase rapidly after the three-phase currents are simultaneously zero, a guide vane adjustment command is issued to the speed governor to limit the unit frequency to the set frequency threshold in advance;

[0123] S405: When the oil pressure exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the operating oil pump;

[0124] S406: If it is detected that the oil pump motor current reaches the locked-rotor current or above, there is no oil flowing into or out of the oil filling pipe, and the oil filling pipe pressure does not rise, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the operating oil pump;

[0125] S407. After detecting an external short circuit in the generator main circuit for an appropriate delay, if the short circuit current has not disappeared, reduce the active power to no-load, generate an external short circuit, and alarm the generator output switch for refusing to trip.

[0126] In this embodiment, the corresponding emergency response type is triggered by setting different starting conditions. In actual implementation, the above steps S401-S407 can be configured in the speed regulator intelligent monitor, and the speed regulator intelligent monitor is then connected to the speed regulator to send corresponding instructions to the speed regulator to enable it to execute the corresponding emergency response content.

[0127] For example, corresponding to the above steps S401-S407, the emergency response content, emergency response type and response purpose corresponding to the start-up conditions are shown in Table 2.

[0128] Table 2 Emergency Response Plan

[0129]

[0130]

[0131] In some embodiments, the smart monitor can communicate directly with people through a voice interaction system, and in case of an emergency, it can also notify the relevant responsible mobile phone through modern communication methods, making it easier for staff to use the smart monitoring system to complete various tasks.

[0132] In some embodiments, an intelligent speed regulator is provided, the structure of which is as follows: Figures 5 to 7 As shown, the intelligent speed regulator is based on the structure of the original speed regulator, and has added an acquisition component, an execution component and a control component that the original speed regulator does not have. The overall structure and function of the intelligent speed regulator do not change. The control component is used to control the execution component to perform corresponding operations based on the signal collected by the acquisition component, so as to improve the reliability and safety of the speed regulator. The specific control method of the control component has been explained in detail in the above embodiments, so it will not be repeated here. The installation position of each acquisition component should fully consider the current status of the equipment, and it is necessary to fully exert the information collection function and ensure the accuracy and integrity of the information. At the same time, the installed components do not affect the appearance of the original equipment and do not increase safety hazards. The control component outputs the execution instruction directly connected to the original equipment, and the relevant disposal is completed through the original equipment, avoiding conflicts with the original equipment instructions.

[0133] Specifically, the intelligent speed regulator includes an oil tank 1, an intelligent oil gauge 2, a safety valve 3, a motor 4, an oil pump 5, an oil filter 6, a check valve 7, an oil drain valve 8, an oil tank 9, an oil pressure sensor for the oil filling pipe 10, an oil pressure sensor for the oil supply pipe 11, a clamp-type flowmeter for the oil supply pipe 12, a clamp-type flowmeter for the oil return pipe 13, a clamp-type flowmeter for the oil filling pipe 14, an oil supply valve 15, a No. 1 energy storage capsule 16, a No. 2 energy storage capsule 17, a hydraulic valve block 18, a hydraulic cylinder 19, an opening sensor 20, an electric contact pressure gauge 21, an infrared thermometer 22, an electronic nose 23, and an infrared camera 24. The hydraulic system is powered by an oil pump, and precise control of the oil flow direction and volume is achieved through multiple valves and sensors. Various monitoring devices ensure safe and stable operation of the system. The energy storage capsule may be used to absorb shock or store energy. The intelligent oil gauge and oil tank ensure sufficient hydraulic oil and monitor the oil level in real time.

[0134] Hydraulic oil flows from the oil tank 9 through the oil drain valve 8 into the motor 4 to drive the oil pump, which pumps the hydraulic oil to the valve 6 and the one-way valve 7. The hydraulic oil passing through the one-way valve 7 flows to the 1# energy storage capsule (16), the 2# energy storage capsule 17 and the hydraulic valve group 18 respectively. The hydraulic valve group 18 controls the flow direction and flow of the oil, and the oil supply valve 15 ensures the safety of the system. The oil filling pipe oil pressure sensor 10, the oil supply pipe oil pressure sensor 11 and the oil filling pipe clamp flow meter 14, the oil supply pipe clamp flow meter 12 monitor the pressure and flow of the oil filling pipe and the oil supply pipe respectively. The opening sensor 20, the infrared thermometer 22, the electric contact pressure gauge 21, the electronic nose 23 and the infrared camera 24 are used to monitor various working status parameters of the system.

[0135] The functions of the various components involved are as follows:

[0136] Left part

[0137] Oil tank 9: stores hydraulic oil.

[0138] Oil drain valve (with maintenance safety lock) 8: used for oil drain, with anti-misoperation function.

[0139] Motor 4: provides power source.

[0140] Safety valve 3: ensures system pressure safety.

[0141] Oil pump (unnumbered): pumps hydraulic oil to provide the required pressure for the system.

[0142] Valve 6: controls the flow direction of oil and realizes the system regulation function.

[0143] One-way valve 7: allows hydraulic oil to flow in one direction and prevents backflow.

[0144] Oil-filled pipe clamp flowmeter 14: measures the flow rate of the oil-filled pipe.

[0145] Oil filling pipe oil pressure sensor 10: monitors the oil pressure of the oil filling pipe.

[0146] 1# Energy storage capsule 16: stores energy and may be used for system regulation.

[0147] 2# energy storage capsule 17: also used to store energy.

[0148] Hydraulic valve group 18: contains multiple hydraulic control valves for finely controlling the flow of oil.

[0149] Oil supply valve (with maintenance safety lock) 15: controls oil supply and has anti-misoperation function.

[0150] Opening sensor 20: monitors the opening of the hydraulic system.

[0151] Infrared thermometer 22: measures system temperature.

[0152] Electric contact pressure gauge 21: monitors system pressure.

[0153] Electronic nose 23: used to monitor the odor parameters of oil.

[0154] Infrared camera 24: monitors the working status of the hydraulic system.

[0155] Oil tank 1: stores hydraulic oil for system use.

[0156] Smart oil level indicator 2: real-time monitoring and display of oil level.

[0157] The above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. Ordinary technicians in the relevant technical field may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, all equivalent technical solutions also fall within the scope of the present invention. The scope of patent protection of the present invention should be defined by the claims.

Claims

1. A speed regulator intelligent monitoring method, characterized in that: The method comprises: The signal acquisition components and actuators are arranged in the following manner: an oil pressure sensor and a flow meter are installed on the governor oil filling pipe, the oil supply pipe, and the oil return pipe respectively; an opening sensor and a noise meter are installed in the water machine room, and an infrared camera is installed on the top of the governor oil tank; an infrared thermometer, a noise meter, and an electronic nose are installed outside the oil pump motor; an opening and closing current transformer and a voltage transformer are installed in the main electrical circuit of the oil pump motor respectively; an opening and closing current transformer is installed in the secondary circuit of the current transformer at the generator outlet and the secondary circuit of the current transformer on the access line. Based on the signal data collected by the signal acquisition component, a continuous curve is formed according to time; wherein the signal data includes at least one of oil pressure, flow, oil temperature, oil level, oil quality, noise, odor, opening, current, and voltage; Performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera; Based on the set start-up conditions and the real-time collected signal data, when the set start-up conditions are met, the emergency response plan is activated and the corresponding emergency response is performed.

2. A speed regulator intelligent monitoring method according to claim 1, characterized in that: Based on the continuous curve and / or the video data collected by the infrared camera, an advanced fault diagnosis and warning is performed before an accident occurs, including: When the oil pressure drops to the first oil pressure threshold and oil flows out of the oil filling pipe, an emergency oil pressure warning is executed; When the oil pressure rises to the second oil pressure threshold, the oil pump motor has working current and oil flows out of the oil filling pipe, the oil pressure high warning is executed; When the oil pressure drops to the third oil pressure threshold and the main pump motor has no working current, or when the oil pressure drops to the fourth oil pressure threshold and the standby pump motor has no working current, or when the oil pressure rises to the fifth oil pressure threshold and the oil pump motor has working current, or the oil pump motor has working current, the governor oil pressure does not rise and there is no oil flowing in the oil supply pipe, or the oil pump motor has working current and there is oil flowing in the oil supply pipe, but the average oil pressure rising speed is slower than before and exceeds the set threshold, or the oil pump current is larger than the normal working current or there is a phase loss, an abnormal fueling warning is executed; When the oil pump motor operating current lasts longer than the set time, the flow meter measures the oil volume entering the oil storage tank and increases beyond the set threshold, and the oil level in the tank decreases, the capsule abnormality warning is executed; When there is no oil flowing out of the oil supply pipe, the oil pressure drops and / or the oil level in the fuel tank drops gradually, and the oil supply of the oil supply pipe is greater than the oil return of the oil return pipe in multiple time periods, a pipeline oil leakage warning is executed; According to the ambient air temperature and oil temperature change curve, when the ambient temperature remains unchanged or drops, the oil temperature in the fuel tank rises. When the oil temperature is greater than 40°C, an abnormal oil temperature warning is executed; When the speed governor receives a command and there is no oil flow in the oil supply pipe and the oil return pipe / or there is no action command for the valve, but there is oil flow in the oil supply pipe and the oil return pipe, the valve fault warning is executed; When any signal acquisition component interrupts uploading data or continuously generates abnormal data, an input information abnormality warning is executed; When the guide vane opening keeps changing, the valve keeps moving, and there is oil flow in both the oil supply pipe and the oil return pipe, an opening twitch warning is executed; When the ammeter, voltmeter, and power meter swing periodically and the swing amplitude exceeds the set amplitude, a system oscillation warning is executed; When the unit is running under load and the guide vane opening gradually decreases without adjustment, a slip load warning is executed; When the remote controller sends a governor operation command, there is no oil flow in the oil supply pipe and return pipe, and the guide vane opening does not change, a remote control failure warning is executed; When the speed governor automatically runs in the no-load state and the unit frequency cannot be stabilized within the set frequency threshold range, a no-load unit frequency warning is executed; When an abnormal odor is detected that exceeds the standard, an odor abnormality warning is executed; When the sound type or volume exceeds the standard, an abnormal sound warning is issued.

3. The method for intelligent monitoring of a speed regulator according to claim 1, wherein: Performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes: Use the following methods to determine the failure of the oil pressure device capsule: Based on theoretical calculation and actual measurement, the function curves of the oil filling volume and capsule pressure and the oil filling volume and time of the two capsules are obtained, and the total oil filling volume V0 of the two capsules from the start-up oil pressure to the rated oil pressure is calculated; During actual operation, each time the pressure oil increases from the pump start pressure to the rated oil pressure, the actual oil filling volume V1 is calculated using the flow rate measured by the flow meter and the corresponding time, and compared with the total oil filling volume V0 during debugging. If the difference exceeds the normal error and the oil filling time increases compared to the previous one, a capsule abnormality warning is issued; The actual oil filling volume of the faulty capsule is obtained by subtracting the oil filling volume V0 / 2 of the two capsules during the original debugging from the actual oil filling volume. The residual pressure value of the faulty capsule is calculated by comparing the oil filling volume obtained during debugging with the function curve of the capsule pressure. Based on the oil filling volume and time function curve obtained from debugging, the two pumps are started to fill oil separately, and the pump with shorter filling time is determined. The capsule close to the pump with shorter filling time is identified as the faulty capsule.

4. A speed regulator intelligent monitoring method according to claim 3, characterized in that: Before debugging based on theoretical calculations and actual measurements, methods for determining oil pressure device capsule failures also include: When filling nitrogen into two capsules of the same model, the pressure is equal, and the volumes of two pressure oil tanks of the same model are set to be equal and directly connected; When the oil pump is set to fill the oil tank with pressurized oil, the pressures on the two capsules are equal, the volumes of the nitrogen in the capsules contracted by pressure are equal, and the volumes of pressurized oil filled in the two pressure oil tanks are also equal.

5. The method for intelligent monitoring of a speed regulator according to claim 1, wherein: Performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes: Based on the real-time monitoring of the three-phase current of the grid-connected outgoing line, when it is detected that the three-phase current suddenly and quickly drops to zero, and the rate of change and starting point both exceed the set value, the unit frequency and voltage rise rapidly, and the generator output circuit breaker is in the closed state, a remote load shedding alarm is immediately issued.

6. A speed regulator intelligent monitoring method according to claim 2, characterized in that: When warning of oil leakage in the pipeline, the method further includes: determining the amount of oil leakage based on the amount difference time function.

7. A speed regulator intelligent monitoring method according to claim 6, characterized in that: Determine the oil leakage amount based on the quantity difference time function, including: The oil leakage of the oil pipeline per unit time is calculated by the difference between the equivalent oil supply volume of the oil supply pipeline to the relay and the oil return volume of the return pipeline per unit time; When the oil leakage in the oil pipeline exceeds the normal metering error per unit time, an oil leakage warning is immediately issued. The amount of oil leaked is calculated based on the leakage start time and the amount difference time function.

8. The method for intelligently monitoring a speed regulator according to claim 1, wherein: Performing fault diagnosis and early warning according to the continuous curve and / or the video data collected by the infrared camera includes: Under various power supply voltages, multiple sets of current-time curves are generated and stored based on the current changes during the process of the oil pressure rising from the starting pressure to the rated oil pressure after the oil pump is started. By detecting the power supply voltage, starting current, normal working current and duration, the actual current-time curve is obtained; The actual current-time curve is compared with the stored current-time curve. When it is detected that the actual starting current and working current are significantly higher than the stored curve current for multiple times, or the current is missing and lasts for more than 2 seconds, or a short circuit current occurs, or the current exceeds the stall current and lasts for more than 1 second, an oil pump fault warning is immediately issued and the oil pump is controlled to stop running.

9. The method for intelligent monitoring of a speed regulator according to claim 1, wherein: Based on the set start conditions and the real-time collected signal data, when the set start conditions are met, the emergency response plan is activated, including: When the speed governor executes a fast oil use command, and the speed governor oil pressure is lower than the sixth oil pressure threshold and the working pump motor has no working current, the standby oil pump is started in advance to pump oil, and stops pumping oil after reaching the set pressure; When the power supply to the plant is lost during an accident shutdown and the oil pressure drops to the starting pressure, the emergency power supply is immediately used to pump oil; When the ammeter, voltmeter, and power meter oscillate periodically, reduce the active load and then fix the opening; When the three-phase currents of the outgoing current transformers are simultaneously zero, the duration of simultaneous zero is more than 10 seconds, the current is not less than 10% of the rated current 3 seconds before the three-phase currents are simultaneously zero, and the unit frequency and voltage rise rapidly after the three-phase currents are simultaneously zero, a guide vane adjustment instruction is sent to the speed governor to limit the unit frequency to the set frequency threshold in advance; When the oil pressure exceeds the set oil pressure threshold and the oil pump motor has normal operating current, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump; When it is detected that the oil pump motor current reaches the locked-rotor current or above, there is no oil flowing into or out of the oil filling pipe, and the oil filling pipe pressure does not rise, the oil pump thermal relay normally closed circuit is disconnected through the passive node after a 1-second delay, forcibly stopping the working oil pump; After detecting an external short circuit in the generator main circuit with an appropriate delay, if the short circuit current has not disappeared, the active power is reduced to no-load, an external short circuit is generated, and the generator output switch refuses to trip and gives an alarm.

10. The method for intelligent monitoring of a speed regulator according to claim 1, wherein: The method also includes: installing maintenance anti-error locks on the governor oil supply main valve and pressure relief valve, and connecting position information and electromagnetic command transmission lines to the governor intelligent monitor to provide reliable locking for governor maintenance safety.

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