Method and system for detecting abrasion loss of runner of impulse turbine

Abstract

The invention discloses an impulse turbine runner abrasion loss detection method and system, an unmanned aerial vehicle hangar with a sealing door is arranged on a shell of an impulse turbine, and an unmanned aerial vehicle is placed in the unmanned aerial vehicle hangar; after the water-turbine generator set stops, the unmanned aerial vehicle is controlled to fly in the machine shell according to a set planning route, and a rotating wheel of the impulse turbine is scanned through scanning equipment carried on the unmanned aerial vehicle; and generating an actual model of the runner at the current moment based on the scanned data, comparing the actual model with a reference model of the runner, and determining the abrasion loss of the runner. The unmanned aerial vehicle hangar is arranged in the machine shell, the automatic scanning technology is adopted, non-contact type three-dimensional model comparison is achieved, high-precision three-dimensional abrasion detection can be achieved without disassembling the rotating wheel, and the detection efficiency and precision are remarkably improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of water turbine equipment detection, and in particular relates to a method and system for detecting the wear of an impulse turbine runner. Background Art

[0002] The Pelton turbine housing houses the nozzle, regulating device, and runner. The runner is the core component of the Pelton turbine, and its performance directly impacts its operating efficiency and service life. Cavitation and wear are the primary damage mechanisms to the runner, significantly reducing the turbine's energy conversion efficiency. Previous inspection methods for Pelton turbine runners have numerous shortcomings: Using inspection templates to measure depth against the runner's bucket lines requires downtime and disassembly, making the operation complex and time-consuming. The contact method, which involves tracing the damaged area onto paper and calculating the area using a planimeter or graph paper, suffers from low measurement accuracy and inability to reflect three-dimensional morphological features. The plastic material filling method suffers from large material deformation errors and cumbersome operation. These traditional inspection methods are not only inefficient but also struggle to obtain accurate wear data, making them ineffective in providing reliable support for runner maintenance decisions. Particularly in large hydropower plants, traditional inspection methods require significant manpower and resources, and require long inspection cycles, severely impacting unit availability and power generation efficiency. Summary of the Invention

[0003] The purpose of the present invention is to address the shortcomings of the above-mentioned background technology and to provide a method and system for detecting the wear of an impulse turbine runner, which has the advantages of achieving high-precision three-dimensional wear detection without disassembling the runner and significantly improving detection efficiency and accuracy.

[0004] The technical solution adopted by the present invention is: a method for detecting the wear of an impulse turbine runner, wherein a drone hangar with a sealed door is provided on the casing of the impulse turbine, and a drone is placed in the drone hangar; After the hydro-generator unit is shut down, the drone is controlled to fly along a set route within the casing, and the runner of the impulse turbine is scanned by the scanning equipment carried by the drone. An actual model of the wheel at the current moment is generated based on the scanned data, and the actual model is compared with a reference model of the wheel to determine the amount of wear on the wheel.

[0005] Furthermore, the drone hangar is arranged on a side of the casing close to the corridor and protrudes from the outer side of the casing. The drone hangar is a closed space with a sealed door.

[0006] Furthermore, the height difference between the bottom of the drone hangar and the bottom surface of the casing is 0.5-2m.

[0007] Furthermore, the sealing door includes a first sealing door and a second sealing door. The first sealing door is arranged on the casing and is flush with the inner wall of the casing in a closed state. The second sealing door is arranged on a side close to the corridor.

[0008] Furthermore, the drone hangar is provided with a parking platform, a platform slide, and a pushing device. The drone is placed on the parking platform, and the parking platform slides with the platform slide. The pushing device is arranged under the parking platform, and the pushing device is used to push the parking platform along the platform slide into the interior of the casing.

[0009] Furthermore, the ejection device is a screw-nut structure, a gear rack structure, or a chain (belt) structure.

[0010] Furthermore, the drone hangar is also equipped with a wireless charging module, a wireless data transmission module, and a drone navigation module. The wireless charging module, wireless data transmission module, and drone navigation module are all installed on the parking platform. The wireless charging module is used to charge the drone and the scanning device, the wireless data transmission module is used to transmit the data scanned by the scanning device, and the drone navigation module is used to provide positioning and navigation services for the drone.

[0011] Furthermore, the scanning device is a three-dimensional laser scanner.

[0012] Furthermore, the reference model is an actual model of the running wheel generated by a certain measurement before the current moment, or the reference model is an original model of the running wheel.

[0013] Furthermore, the comparison refers to calculating the thickness difference between corresponding positions on the actual model and the reference model, the areas corresponding to different thickness differences, and the areas corresponding to different areas.

[0014] A system for detecting the wear of a runner of an impulse turbine comprises a drone hangar with a sealed door installed on a casing of the impulse turbine, a drone, and a control module, wherein the drone is equipped with a scanning device; The control module is used to control the drone to fly along a set planned route within the casing after the hydro-generator set is shut down, and to control the scanning equipment to scan the runner of the impulse turbine, generate an actual model of the runner at the current moment based on the scanned data, compare the actual model with the benchmark model of the runner, and determine the amount of wear on the runner.

[0015] The beneficial effects of the present invention are: The present invention sets up a drone hangar inside the turbine casing, eliminating the need for operators to enter the casing for measurement. Instead, a drone equipped with a laser scanner is used to automatically scan the runner from various angles according to a planned route, generating a complete high-precision runner model. Based on comparative analysis of the scanned models at different time points, the present invention detects data such as the wear depth and area of ​​the unit's runner bucket surface, thereby reducing the labor intensity of operators and improving the frequency, efficiency, and quality of wear detection of the impulse turbine runner. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the principle of the detection system of the present invention.

[0017] Figure 2 Schematic diagram of the drone hangar of the present invention.

[0018] In the figure, 1-casing; 1.1-side; 1.2-inner wall; 1.3-bottom; 2-rotating wheel; 3-corridor; 4-control module; 5-UAV hangar; 5.1-first sealed door; 5.2-second sealed door; 5.3-bottom; 6-UAV; 7-parking platform; 8-platform slide; 9-ejection device; 10-wireless charging module; 11-wireless data transmission module; 12-UAV navigation module. DETAILED DESCRIPTION

[0019] The following is a further description of specific embodiments of the present invention in conjunction with the accompanying drawings. It should be noted that the description of these embodiments is intended to facilitate understanding of the present invention and does not constitute a limitation of the present invention. In addition, the technical features involved in the various embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

[0020] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as limiting the present invention.

[0021] To overcome the technical bottlenecks of traditional inspection methods, which often involve complex manual operations and incomplete data collection, a non-contact, automated inspection system is needed. First, the storage of inspection equipment in humid environments must be addressed to prevent water mist erosion. Second, full 3D scanning must be achieved to eliminate blind spots in manual inspections. Finally, a high-precision model comparison mechanism must be established to overcome the limitations of 2D measurement. Automating the inspection process and eliminating human operational risks by integrating drone platforms with 3D scanning technology has become a key area of ​​technical improvement.

[0022] Based on the above principle, the present invention provides a method for detecting the wear of an impulse turbine runner. Figure 1 、 Figure 2 As shown, a drone hangar 5 with a sealed door is provided on the casing 1 of the impulse turbine, and a drone 6 is placed in the drone hangar 5; after the hydro-generator set is shut down, the drone 6 is controlled to fly within the casing 1 according to a set planned route, and the runner 2 of the impulse turbine is scanned by the scanning equipment carried by the drone 6; the actual model of the runner at the current moment is generated based on the scanned point cloud data, and the actual model is analyzed and compared with the benchmark model of the runner to determine the wear amount of the runner.

[0023] The drone hangar 1 with a sealed door refers to a waterproof and sealed equipment storage compartment, specifically constructed using a metal casing and a rubber sealing ring. This structure isolates moisture from the interior of the casing, ensuring the safe storage of the drone when not in operation. Planned flight refers to a pre-programmed drone flight trajectory, achieved through a lidar positioning system. This path covers the entire surface area of ​​the rotor, ensuring comprehensive scanning. A scanning device refers to a three-dimensional spatial data acquisition device, such as a phased laser measurement unit, which acquires surface coordinate information by transmitting and receiving laser beams. Generating an actual model from point cloud data involves converting a discrete three-dimensional coordinate point set into a continuous surface model, which can be achieved using a triangular mesh reconstruction algorithm. Benchmark model comparison analysis involves calculating the geometric deviation between the actual model and the reference model using three-dimensional model registration techniques. Specifically, an iterative closest point algorithm can be used to align coordinates and then calculate thickness differences.

[0024] Specifically, when the turbine generator unit shuts down, the sealed door opens, allowing the drone to enter operational mode. The drone orbits the runner along a pre-set path, its onboard scanning device emitting laser beams at a fixed frequency, recording the spatial coordinates of tens of thousands of measurement points on the runner surface. The scanned data is wirelessly transmitted to a processing terminal, where point cloud filtering and surface reconstruction are used to generate a digital model consistent with the physical object. This model is spatially aligned with a historical benchmark model, and the wear depth distribution of the bucket surface is precisely quantified by calculating the normal distance difference between corresponding mesh vertices. Finally, the wear area statistics and maximum wear parameters are output, providing data support for maintenance decisions.

[0025] Compared with existing technologies, traditional manual inspection requires waiting for the machine to shut down and the internal environment to stabilize, and personnel wearing protective gear to perform inspections. This poses safety risks such as falls and mechanical injuries. This solution completely replaces manual inspections with automated drone operations, reducing inspection time to one-fifth of the original method. 3D laser scanning can achieve a measurement point density of millions per square meter, significantly superior to single-point measurement using template comparison methods. The model comparison algorithm can identify deformations as small as 0.1 mm, improving inspection accuracy by over ten times compared to traditional contact measurement.

[0026] Through the above technical solution, the present invention realizes non-contact automated detection, eliminating the safety hazard of manual entry into the casing; the three-dimensional scanning technology completely obtains the geometric characteristics of the wheel surface, overcoming the measurement blind spots of the sample comparison method; high-precision model comparison can quantify subtle wear deformation, providing accurate data support for equipment status assessment; the detection process is fully automated, so that the frequency of wheel wear detection can be increased from annual detection to monthly detection, significantly improving the timeliness of equipment maintenance, and has the advantages of realizing high-precision three-dimensional wear detection without disassembling the wheel, significantly improving detection efficiency and accuracy.

[0027] The present invention further proposes to set a drone hangar 5 protruding from the outer side of the casing 1 of the impulse turbine on one side close to the corridor 3. The drone hangar 5 is a closed space and is provided with a sealed door. The height difference h between the bottom 5.3 of the drone hangar 5 and the bottom surface 1.3 of the casing 1 is set to 0.5-2m, preferably 1m or 1.5m.

[0028] Among them, the side close to the corridor 3 refers to the installation location of the drone hangar 5, which is adjacent to the passage area where the crew operation and maintenance personnel pass on a daily basis, making it convenient to approach the hangar through the corridor to carry out drone pick-up and placement operations. The arrangement 1.1 protruding from the outer side of the casing 1 means that the main structure of the hangar extends outward beyond the outer surface plane of the casing to avoid occupying the internal space of the casing and reducing interference with the rotor detection operation. The closed space means that the hangar adopts a fully enclosed structure, forming an independent cavity inside to prevent external moisture or impurities from intruding. The sealed door can adopt a double-layer door structure, such as an outer waterproof door and an inner isolation door combined to isolate the high humidity environment inside the casing. The height difference of 0.5-2m means that a specific distance is maintained between the bottom plane of the hangar and the bottom plane of the casing, for example, by installing a support frame or adjusting the height of the mounting base. This distance can facilitate the operator to maintain the drone and the hangar, and at the same time provide space for the layout of pipelines under the hangar.

[0029] Specifically, the drone hangar, installed near a corridor, allows operators to access the hangar directly through the corridor, eliminating the need to enter complex equipment areas to store and retrieve drones. The hangar's raised design allows drones to enter and exit the hangar during inspections without entering the wheel work area, preventing interference between maintenance drones and unit operations. The enclosed structure and sealed doors create a dry storage environment. For example, when the unit is operating, the closed doors prevent water mist from entering the hangar, protecting the drone equipment from corrosion. A height difference in the floor provides maintenance personnel with sufficient clearance to inspect the hangar floor.

[0030] Through the above technical solution, the present invention solves the problem of compatibility between drone storage space and the unit structure. Operators can directly access drones through conventional operation and maintenance channels, avoiding the risk of entering high-risk areas. The hangar's raised exterior layout is completely separated from the interior space of the housing, without changing the original internal design, eliminating the risk of equipment collision. The closed structure and specific height differences ensure structural stability while facilitating maintenance and extending the service life of the drone equipment.

[0031] The present invention further proposes that the sealing door includes a first sealing door 5.1 and a second sealing door 5.2. The first sealing door 5.1 is arranged on the casing 1. When the first sealing door 5.1 is closed, it is flush with the inner wall 1.2 of the casing 1 to isolate the water mist in the casing; the second sealing door 5.2 is arranged on the side close to the corridor 3, and the second sealing door 5.2 is used for operators to take and place the drone.

[0032] The first sealing door 5.1 is a partition between the housing 1 and the drone hangar 5. It can be implemented using a mechanical sliding seal. When closed, its surface forms a continuous plane with the housing's inner wall, blocking the path for water mist infiltration. The second sealing door 5.2 is an independent passageway component located on the outer wall of the drone hangar 5. It can be implemented using a hinged opening and closing structure. Its position spatially corresponds to the maintenance corridor, creating an operating interface independent of the interior of the housing.

[0033] Specifically, when the turbine is in a shutdown state, the first sealing door 5.1 is opened by sliding along the inner wall of the casing through a sliding rail mechanism or rotating through a hinge, so that the drone hangar 5 is connected to the inside of the casing 1. When the turbine enters the operating state, the first sealing door 5.1 is closed and forms a continuous closed surface with the inner wall 1.2 of the casing 1, preventing high-pressure water mist from invading the drone storage space; the second sealing door 5.2 is opened by rotating through a hinge, providing the operator with a physical passage on the corridor side. After the second sealing door 5.2 is opened, an inspection and operation surface independent of the operating environment inside the casing is formed, and maintenance personnel perform drone maintenance operations through the corridor side channel. The two sealing doors realize functional zoning through spatial isolation design. The first sealing door assumes the dynamic environment isolation function, and the second sealing door assumes the static maintenance operation function.

[0034] This solution establishes a parallel system of physical isolation layer and operation channel through a double sealed door structure, which not only meets the high-pressure water mist barrier requirements during the operation of the runner, but also provides an independent operation interface during the shutdown maintenance phase.

[0035] Through this technical solution, the present invention effectively addresses the issue of drone storage space being susceptible to water mist erosion during operation, while also ensuring that maintenance personnel can complete drone access operations in a non-invasive environment. The first sealed door uses a mechanical seal to block water mist contamination, while the second sealed door optimizes the human-machine interaction path through an independent channel design. These two work together to extend the life of the drone equipment and improve inspection efficiency.

[0036] The present invention further proposes to set up a parking platform 7, a platform slide 8 and a pushing device 9 in the drone hangar 5. The parking platform 7 and the platform slide 8 are slidably matched. The pushing device 9 is set under the parking platform 7 and is used to push the parking platform 7 along the platform slide 8 into the interior of the casing 1. The pushing device 9 adopts a screw nut structure, a gear rack structure or a chain (belt) structure.

[0037] Among them, the parking platform 7 refers to the planar structure that supports the drone, which can be specifically implemented by a metal frame and a non-slip surface, and is used to stabilize the storage position of the drone to avoid equipment collisions due to limited space in the hangar. The platform slide 8 refers to a track mechanism that slides with the parking platform 7, which can be specifically implemented by a linear guide rail and a slider assembly, and is used to constrain the motion trajectory of the parking platform to ensure that there is no offset during the ejection process. The ejection device 9 refers to a mechanical transmission mechanism that drives the parking platform to move, and can specifically adopt a screw and nut structure to achieve linear propulsion, a gear rack structure to achieve power transmission, or a chain (belt) structure to achieve continuous transmission, which is used to provide stable driving force and adapt to different installation space requirements.

[0038] Specifically, when the drone needs to perform an inspection task, the ejection device 9 drives the parking platform 7 to move outward along the platform slide 8 from the inside of the hangar until the front end of the parking platform is cantilevered over the internal space of the casing. In the cantilevered state, the parking platform 7 forms a temporary take-off and landing plane extending to the inspection area. Figure 2 The dashed line in the center illustrates the cantilevered landing platform within the hangar housing. Drone 6 can launch directly from this platform to perform scanning operations. After inspection, drone 6 returns to landing platform 7, where ejector mechanism 9 reverses and retracts the platform along slide 8 back into the hangar. This entire process utilizes a mechanical transmission mechanism to automate the loading and unloading of drones, eliminating the risk of equipment falling due to manual handling.

[0039] The present invention uses a mechanized ejection device in conjunction with a slide to enable the UAV to complete storage and inspection position transfer in a closed hangar without the need for direct human intervention, while preventing the erosion of the UAV equipment by residual water mist in the casing; at the same time, the stable ejection and retraction of the parking platform are achieved through a mechanical transmission structure, reducing the risk of manual operation and improving the degree of automation of the inspection process.

[0040] The present invention further proposes that the drone hangar is also provided with a wireless charging module 10, a wireless data transmission module 11, and a drone navigation module 12. The wireless charging module 10, the wireless data transmission module 11, and the drone navigation module 12 are all installed on the parking platform. The wireless charging module 10 is used to charge the drone and the scanning device, the wireless data transmission module 11 is used to transmit the data scanned by the scanning device, and the drone navigation module 12 is used to provide positioning and navigation services for the drone.

[0041] The wireless charging module 10 is a device that achieves contactless power transmission through electromagnetic induction or magnetic resonance. Specifically, it can be implemented using a wireless charging circuit board based on the Qi standard or A4WP standard. Its transmitter is embedded in the surface of the parking platform, and the receiver is integrated into the bottom of the drone. This is used to eliminate the electrical safety hazards of wired charging in a water mist environment inside the casing. The wireless data transmission module 11 is a component that transmits point cloud data in real time based on a wireless communication protocol. Specifically, it can be implemented using a Wi-Fi 6 or 5G millimeter wave communication module. By deploying a directional antenna array inside the casing to enhance signal coverage, it is used to solve the problem of data return delay in obscured areas. The drone navigation module 12 is a combined navigation device that integrates visual SLAM with UWB ultra-wideband positioning technology or other indoor space navigation technology solutions such as ultrasonic and infrared. Specifically, it can be implemented using a binocular camera and UWB anchor base station collaborative positioning method. The anchor base stations can be arranged in a ring along the inner wall of the casing to eliminate positioning deviations caused by the lack of GPS signals. Figure 2 The positions of the wireless charging module 10, the wireless data transmission module 11, and the drone navigation module 12 are shown for reference only, and their specific installation positions are determined according to actual application requirements.

[0042] Specifically, when the drone 6 is docked on the parking platform 7, the wireless charging transmitting coil on the platform surface is automatically aligned with the receiving coil at the bottom of the drone, and power is supplied to the drone battery and scanning equipment through magnetic resonance coupling, avoiding manual entry into a high-humidity environment to plug in and unplug the charging interface. During the flight detection process, the three-dimensional point cloud data collected by the scanning equipment is uploaded to the control module in real time via the 5G millimeter wave channel of the wireless data transmission module, avoiding the problem of increased drone load and restricted flight path caused by traditional wired transmission. At the same time, the drone navigation module transmits a positioning signal through the UWB anchor base station preset in the casing, and combines the visual features captured by the onboard binocular camera to construct a positioning map based on multi-sensor fusion, so that the drone can still fly stably along the planned path in a closed space without an external GPS signal. The present invention realizes autonomous energy replenishment through wireless charging, ensures data real-time performance through high-speed wireless transmission, and improves the positioning accuracy of closed spaces through combined navigation. The three work together to achieve a fully automated closed loop of the detection process.

[0043] The present invention further proposes the use of a three-dimensional laser scanner in the scanning device, which is capable of 360° rotation, with a vertical field of view covering a range of -90° to 90° and a measurement accuracy of 0.02mm.

[0044] A 3D laser scanner is a device that uses laser ranging principles to obtain three-dimensional coordinate data on an object's surface. This can be achieved using phased or pulsed laser scanning technology. Its purpose is to obtain complete point cloud data on the rotor surface through non-contact measurement, avoiding surface damage caused by traditional contact methods. 360° rotation refers to the scanner's full rotation around its own axis, achieved by a stepper motor-driven rotating base. This eliminates blind spots and covers complex curved surfaces such as the rotor's bucket lines. A vertical field of view of -90° to 90° means the scanner has a 180° scanning angle range in pitch, achieved by a multi-axis pan-tilt mechanism. This ensures complete scanning of the rotor's top and bottom areas. A measurement accuracy of 0.02mm means that the positional error of a single point is kept within this value. This is achieved through the combination of a high-precision laser transmitter and receiver. This allows for the detection of subtle deformations on the rotor surface caused by cavitation or wear.

[0045] Specifically, when the drone carrying the 3D laser scanner enters the casing, it forms a three-dimensional scanning network around the runner through 360° horizontal rotation combined with 180° vertical scanning coverage. During the flight, the scanner continuously emits laser beams and receives reflected signals, and obtains the three-dimensional coordinates of each measuring point by calculating the laser flight time difference. Since data collection can be completed without contacting the runner surface, it avoids the limitations of the traditional template comparison method on the operating space and eliminates the secondary damage that may be caused by contact measurement. For parts with complex curved surfaces such as the runner bucket, the wide-angle vertical field of view can ensure the complete capture of the contour line, and the high-precision measurement capability can distinguish surface deformation differences at the micron level.

[0046] Compared to existing technologies, traditional inspection methods require manual copying or contact measurement of a sample, which can lead to incomplete data collection and the omission of hidden areas. However, this invention leverages the all-around coverage of a 3D laser scanner to achieve comprehensive inspection of the rotor surface. Compared to contact methods that require long downtime and operation, this non-contact measurement method can scan the entire surface in a single drone flight, significantly improving inspection efficiency.

[0047] Through the above technical solution, the present invention solves the technical problems of insufficient accuracy and incomplete coverage of traditional detection methods, realizes high-precision quantitative detection of the amount of wear on the impeller surface, avoids measurement errors that may be caused by manual operation, and effectively shortens the time window for shutdown detection of the turbine unit.

[0048] The present invention further proposes that the reference model is composed of an actual model of the runner generated by a certain measurement before the current moment or an original model of the runner when it leaves the factory.

[0049] The benchmark model refers to a standard 3D model used as a reference for wear calculations. This can be achieved using historical point cloud data acquired by a 3D laser scanner. Selecting benchmark models from different sources provides a multi-dimensional comparison basis for wear analysis. The actual model of the wheel, generated by a measurement prior to the current moment, is a dynamic benchmark established through periodic scanning. This can be achieved by reconstructing a model using point cloud data from a specific inspection cycle. Wear trends are tracked by establishing a time-series model sequence, with the actual model of the wheel generated by the most recent measurement being the preferred benchmark model.

[0050] Specifically, during turbine downtime inspections, the accumulated wear of the turbine since commissioning can be calculated by comparing the actual model generated by the current scan with the original factory model. By selecting the actual model generated by a previous inspection as a baseline, the wear rate over a specific time period can be analyzed. For example, during annual inspections, the factory model can be used as a baseline to assess the overall wear status of the turbine; during quarterly inspections, the model from the previous quarter can be used as a baseline to quantify incremental wear. The dynamic selection mechanism for baseline models enables wear analysis to simultaneously meet the dual requirements of authoritative benchmark verification and local change tracking, eliminating inspection errors caused by a single benchmark.

[0051] By introducing historical actual models as replaceable benchmarks, this invention ensures that test results maintain comparability with original design data while also enabling analysis of dynamic wear characteristics through the overlay of time-series models. This enhances the dimensionality of wear assessment and enables longitudinal trend analysis and multi-stage comparative verification of runner wear. During the test process, by selecting benchmark models at different time points, it is possible to accurately distinguish between cumulative wear and staged wear, avoiding the drawback of a single benchmark that fails to reflect local changes, thereby improving the reliability of test data and the depth of analysis.

[0052] The present invention further proposes to generate an actual model of the current runner based on the scanned point cloud data, analyze and compare the actual model with the benchmark model of the runner, and determine the wear amount of the runner by calculating the thickness difference between the corresponding positions on the actual model and the benchmark model, dividing the areas corresponding to different thickness differences, and counting the areas corresponding to different areas.

[0053] Among them, the thickness difference at corresponding positions refers to the difference in the model surface spacing calculated at the same coordinate point after the actual model and the reference model are spatially aligned through the three-dimensional coordinate system matching algorithm. Specifically, this can be achieved by using the ICP (Iterative Closest Point) algorithm based on point cloud registration. This feature ensures the spatial consistency of model comparison. The areas corresponding to different thickness differences refer to dividing the thickness difference data into multiple levels according to a preset threshold range. Each level corresponds to a specific wear degree interval. Specifically, this can be achieved by using a color coding algorithm to partition and color the three-dimensional model surface. This feature realizes the visual grading of the wear degree. The area corresponding to different regions refers to the automatic calculation and statistics of the model surface area covered by each thickness difference level. Specifically, this can be achieved by using the triangular patch integration method to accumulate the area of ​​the three-dimensional mesh model. This feature establishes a quantitative relationship between the degree of wear and the scope of influence.

[0054] Specifically, after the actual model and the reference model are 3D-aligned, the thickness deviation of each vertex in the normal direction is calculated by traversing the coordinates of all vertices on the model surface. When the thickness difference exceeds a set threshold, the wear level region to which the vertex belongs is automatically marked. For each divided region, the projected area of ​​all triangular facets within the region is accumulated based on the topological structure of the 3D mesh, and the total surface area corresponding to each thickness difference level is finally output. This forms a hierarchical analysis system from microscopic point cloud data to macroscopic regional area.

[0055] The present invention realizes automatic calculation of full-surface thickness difference through non-contact three-dimensional model comparison, realizes visual positioning of spatial distribution of wear degree based on regional division, and establishes quantitative evaluation index of wear impact range in combination with area statistics. It can accurately quantify the wear thickness difference at each position of the wheel surface, automatically identify the distribution areas of different wear degrees, and accurately count the impact area of ​​each level of wear area, thus solving the technical defect that traditional methods cannot comprehensively evaluate the wear status of the wheel surface.

[0056] The present invention further provides a system for detecting the wear of an impulse turbine runner, comprising a drone hangar 5 with a sealed door, a drone 6, and a control module 4 arranged on a casing 1 of the impulse turbine, wherein the drone 6 is equipped with a scanning device; after the hydro-generator set is shut down, the control module 4 controls the drone 6 to fly along a planned route and controls the scanning device to scan the runner 2, generates an actual model of the runner based on the scanning data, and compares it with a reference model to determine the wear amount.

[0057] Among them, the drone hangar refers to an enclosed space set on the casing, which can be specifically implemented by a double-layer sealed door structure. The outer sealed door isolates external moisture, and the inner sealed door isolates the internal environment of the casing, ensuring that the drone storage environment is dry and stable. The control module refers to an arithmetic unit that integrates flight control and data processing. It is set in a corridor that is convenient for maintenance personnel to operate. It can be implemented by an embedded system and a preset program. The flight trajectory of the drone is planned through a navigation algorithm, and the working sequence of the scanning equipment is coordinated. The scanning equipment refers to a non-contact three-dimensional data acquisition device, which can be implemented by a lidar or a structured light scanner. The point cloud data of the rotor surface is acquired by emitting detection signals. The benchmark model refers to the original three-dimensional data template of the rotor. It can be implemented by a computer-aided design model or historical detection data, which serves as a comparison basis for wear calculation.

[0058] Specifically, when the hydro-turbine generator unit shuts down, the control module first initiates the program to open the sealed door of the drone hangar. Once the internal environment of the housing stabilizes, the drone is controlled to fly along a pre-set path. During flight, a scanning device continuously scans the runner surface, generating a point cloud dataset containing spatial coordinates. After filtering, this point cloud data is input into 3D modeling software to reconstruct the actual runner model. A coordinate registration algorithm is then used to spatially align the actual model with the reference model. The comparative analysis module calculates the thickness deviation at each point on the model surface, calculates the area distribution of areas exceeding the standard, and ultimately generates a quantitative report containing the location and extent of wear.

[0059] The present invention uses a drone equipped with high-precision scanning equipment to achieve non-contact measurement, eliminating measurement errors caused by manual contact; covers the entire surface of the runner through flight path planning, avoiding the visual blind spots that exist in manual inspection; and directly outputs quantitative wear data through digital model comparison, replacing the traditional manual area calculation method.

[0060] Through the above technical solution, the present invention realizes full automated control of the wheel wear detection process, avoiding inspection personnel from entering a dangerous working environment; improves the efficiency of detection data collection, shortening the time required for a single detection from dozens of hours in traditional methods to within 30 minutes; improves the accuracy of detection results, and controls the thickness measurement error within 0.05 mm; generates a three-dimensional visual wear report, intuitively displaying the wear status of various parts of the wheel, and providing data support for subsequent maintenance decisions.

[0061] The present invention further proposes that after the hydro-turbine generator set is shut down, the control module sequentially controls the opening of the first sealed door of the drone hangar, controls the extension of the parking platform into the casing, controls the operation of the drone navigation module, and controls the drone to fly according to the set planned route; the control module controls the scanning module to scan the runner, and the scanning module transmits the scanned point cloud data to the control module through the wireless data transmission module. After the scanning is completed, the control module sequentially controls the drone to stop on the drone platform, controls the drone navigation module to stop working, controls the drone platform to retract into the drone hangar, and controls the closing of the first sealed door.

[0062] The control module refers to the central processing unit (CPU) used to execute automated process instructions. It can be implemented as a programmable logic controller (PLC) or embedded system. It coordinates the coordinated actions of the drone hangar door, landing platform, navigation system, and scanning equipment. The first sealed door is a mechanical structure used to isolate the interior and exterior environments of the enclosure. It can be implemented as a sealed door driven by an electric slide or a hinged door that rotates to open electrically. When closed, it remains flush with the interior wall of the enclosure, preventing water mist from entering the drone hangar. The landing platform is a movable vehicle that supports the drone. It can be implemented as a combination of a metal frame and slides. Driven by a screw nut, rack and pinion, or chain (belt), it extends and retracts along the slides, allowing the drone to move within and outside the enclosure. The drone navigation module provides spatial positioning and path planning for the drone. It can be implemented using multi-sensor fusion indoor navigation technologies such as laser SLAM and UWB, ensuring precise flight within the confined space within the enclosure.

[0063] Specifically, the control module executes sequential instructions in the detection process. First, it opens the first sealed door and pushes the parking platform into the casing to provide a channel for the UAV to enter the operating area. After the UAV navigation module is started, the flight route is loaded into the UAV control unit. The UAV flies along the preset path, and the scanning equipment performs a three-dimensional scan on the surface of the runner. The scanning data is transmitted back to the control module in real time through the wireless transmission module. After the scan is completed, the UAV returns to the parking platform, the platform retracts into the hangar and closes the sealed door. The entire process does not require human intervention. Each link realizes closed-loop operation through the timing instructions of the control module, avoiding the influence of water mist in the casing on the UAV and equipment, and eliminating the error risk caused by manual operation. The present invention realizes the automation of the entire detection process through the control module. The UAV flight path and scanning operation are completed autonomously by the system. The detection process is completely closed to avoid interference from ambient light factors. At the same time, it reduces the human participation links and shortens the detection time.

[0064] Through the above technical solution, the present invention solves the problem of low efficiency caused by the traditional detection method's reliance on manual operation, realizes the standardized execution of UAV detection operations through an automated control process, avoids the corrosion interference of the water mist environment inside the casing on the detection equipment, ensures the integrity of point cloud data collection and the timeliness of transmission, and improves the reliability and repeatability of wheel wear detection.

[0065] It should be noted that the functions implemented by the drone hangar structure, drone and control module in the detection system are the same as those described in the above detection method, so some descriptions will not be repeated here.

[0066] It should be understood that the specific order or hierarchy of steps in the disclosed processes is an example of an exemplary method. Based on design preferences, it should be understood that the specific order or hierarchy of steps in the process can be rearranged without departing from the scope of the present disclosure. The accompanying method claims present elements of the various steps in an exemplary order and are not intended to be limited to the specific order or hierarchy described.

[0067] While the above descriptions of embodiments and examples of the present invention are provided for the purpose of providing a more detailed and complete description of the present disclosure, they are not intended to be the only ways to implement or use the embodiments of the present invention. The embodiments cover features of various embodiments, as well as the method steps and sequences for constructing and operating these embodiments. However, other embodiments may be used to achieve the same or equivalent functionality and sequence of steps.

[0068] The above are only specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be covered by the scope of protection of the present invention. Matters not described in detail in this specification belong to the prior art known to those skilled in the art.

Claims

1. A method for detecting wear of an impulse turbine runner, characterized in that: A drone hangar with a sealed door is provided on the casing of the impulse turbine, and a drone is placed in the drone hangar; After the hydro-generator unit is shut down, the drone is controlled to fly along a set route within the casing, and the runner of the impulse turbine is scanned by the scanning equipment carried by the drone. An actual model of the wheel at the current moment is generated based on the scanned data, and the actual model is compared with a reference model of the wheel to determine the amount of wear on the wheel.

2. The method for detecting wear of an impulse turbine runner according to claim 1, wherein: The drone hangar is arranged on a side of the casing close to the corridor and protrudes from the outer side of the casing. The drone hangar is a closed space with a sealed door.

3. The method for detecting wear of an impulse turbine runner according to claim 2, wherein: The height difference between the bottom of the drone hangar and the bottom surface of the casing is 0.5-2m.

4. The method for detecting wear of an impulse turbine runner according to claim 2, wherein: The sealing door includes a first sealing door and a second sealing door. The first sealing door is arranged on the casing and is flush with the inner wall of the casing in a closed state. The second sealing door is arranged on a side close to the corridor.

5. The method for detecting wear of an impulse turbine runner according to claim 1, wherein: The drone hangar is provided with a parking platform, a platform slide, and a pushing device. The drone is placed on the parking platform. The parking platform slides with the platform slide. The pushing device is arranged under the parking platform. The pushing device is used to push the parking platform along the platform slide into the interior of the casing.

6. The method for detecting wear of an impulse turbine runner according to claim 5, wherein: The ejection device is a screw-nut structure, a gear rack structure, or a chain structure.

7. The method for detecting wear of an impulse turbine runner according to claim 5, wherein: The drone hangar is also equipped with a wireless charging module, a wireless data transmission module, and a drone navigation module. The wireless charging module, wireless data transmission module, and drone navigation module are all installed on the parking platform. The wireless charging module is used to charge the drone and scanning equipment, the wireless data transmission module is used to transmit data scanned by the scanning equipment, and the drone navigation module is used to provide positioning and navigation services for the drone.

8. The method for detecting wear of an impulse turbine runner according to claim 1, wherein: The reference model is an actual model of the running wheel generated by a certain measurement before the current moment, or the reference model is an original model of the running wheel.

9. The method for detecting wear of an impulse turbine runner according to claim 1, wherein: The comparison refers to calculating the thickness difference between corresponding positions on the actual model and the reference model, the areas corresponding to different thickness differences, and the areas corresponding to different areas.

10. A system for detecting wear of an impulse turbine runner, characterized in that: It includes a drone hangar with a sealed door installed on the casing of the impulse turbine, a drone and a control module, wherein the drone is equipped with a scanning device; The control module is used to control the drone to fly along a set planned route within the casing after the hydro-generator set is shut down, and to control the scanning equipment to scan the runner of the impulse turbine, generate an actual model of the runner at the current moment based on the scanned data, compare the actual model with the benchmark model of the runner, and determine the amount of wear on the runner.

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