Method and system for monitoring operation temperature of wind turbine generator

Abstract

The invention provides a wind turbine generator running temperature monitoring method and system, and the method comprises the steps: installing temperature sensors at a generator, a gear box, a main shaft bearing and a cabin environment of a wind turbine generator, and collecting temperature signals in real time; filtering the acquired signal, sending the filtered signal to a reference temperature unit, and comparing the filtered signal with a standard temperature signal to obtain a deviation; calculating a compensation coefficient according to the deviation and performing temperature drift compensation on the signal; and the corrected signal is digitalized by the analog-to-digital conversion module and then input into the controller. A reference temperature unit and a compensation calculation module are arranged in an acquisition system to form an independent calibration loop. The system reads a standard temperature signal in real time and calculates the deviation while collecting the temperature signal, and then performs linear or segmented correction compensation according to the deviation, so that the measurement error of the thermocouple or the thermistor caused by environment temperature change, aging or lead resistance drift can be effectively counteracted, and the output temperature value is always kept consistent with the actual temperature.

Description

Technical Field

[0001] This invention relates to the field of wind turbine technology, and in particular to a method and system for monitoring the operating temperature of wind turbines. Background Technology

[0002] During long-term operation, wind turbine units experience significant internal temperature variations due to factors such as ambient temperature, humidity, and nacelle ventilation. Key components of the unit, such as the generator, gearbox, and main shaft bearings, are prone to heat accumulation under different loads. To ensure safe operation, temperature sensors are typically installed to monitor the temperature of these critical components in real time. However, traditional temperature monitoring systems typically directly collect sensor output signals and upload them to the main control unit, which has the following drawbacks: On the one hand, sensors are prone to temperature drift when exposed to high temperature, high humidity and vibration for a long time, which causes the output signal to deviate from the actual temperature; On the other hand, the existing system lacks an effective on-site calibration and automatic compensation mechanism, and cannot correct measurement errors in real time, resulting in long-term accumulation of errors in temperature records, which affects the accurate judgment of the unit's operating status. Therefore, a method and system for monitoring the operating temperature of wind turbine units are proposed. Summary of the Invention

[0003] In view of this, the present invention provides a method and system for monitoring the operating temperature of wind turbine units, so as to solve or alleviate the technical problems existing in the prior art, and at least provide a beneficial option.

[0004] The technical solution of this invention is implemented as follows: A method for monitoring the operating temperature of a wind turbine generator set, comprising the following steps: S1. Install temperature sensors in the generator, gearbox, main shaft bearing and nacelle environment of the wind turbine to collect temperature signals; S2. Transmit the analog signal output by the temperature sensor to the acquisition module and perform filtering. S3. Obtain the standard temperature signal through the reference temperature unit and compare it with the acquired signal to obtain the deviation value; S4. Calculate the compensation coefficient based on the deviation value and perform temperature drift compensation on the acquired signal; S5. Convert the corrected signal into a digital signal via the analog-to-digital converter and input it into the controller; S6. The controller generates an alarm signal and records the temperature curve according to the set temperature range.

[0005] More preferably, the reference temperature unit adopts a constant temperature structure to maintain the stability of the output signal. The reference temperature unit with a constant temperature structure can maintain a constant output of the reference signal under different external ambient temperatures, and is not affected by changes in cabin ambient temperature, wind speed or day-night temperature difference. By adding a constant temperature heating film and temperature control circuit to the reference unit, the reference temperature fluctuation range can be controlled within ±0.05℃, thereby significantly improving the stability of the standard signal.

[0006] More preferably, the temperature drift compensation calculates the offset of the acquired signal through a linear correction model. By using a linear correction model to compensate for the temperature drift of the acquired signal, real-time and continuous error correction can be achieved. The algorithm is simple, has low computational load, and is easy to embed. By comparing the measured deviation ΔT and correcting it according to the proportional coefficient K, the output of each sampling channel can maintain a linear correspondence with the actual temperature. This compensation method does not rely on complex algorithms and can complete temperature correction using only fixed parameters, which greatly reduces the system's computational burden and response latency, while ensuring long-term stability of compensation accuracy.

[0007] In a further preferred embodiment, the signal is uploaded to the main control unit after A / D conversion for display and recording. By setting an analog-to-digital conversion (A / D) stage in the signal path, the compensated analog voltage signal can be converted into a standardized digital signal, avoiding electromagnetic interference and signal attenuation during long-distance transmission. After receiving the digital signal, the main control unit can directly perform data storage, curve plotting, and historical querying, forming a complete record chain of temperature changes.

[0008] In a further preferred embodiment, the system performs a loop calibration once during the interval between unit startup and shutdown, and performs periodic loop calibration during the interval between unit startup and shutdown. This allows the system to automatically complete self-testing and benchmark updates without affecting the normal power generation operation of the unit. By utilizing the non-operation period for reference path comparison and compensation coefficient refresh, the system ensures that the measurement accuracy is in the optimal state before the start of each operating cycle.

[0009] The present invention also provides a wind turbine operating temperature monitoring system, comprising: Temperature acquisition module is used to collect temperature signals from key parts of the unit; The calibration reference module provides a standard temperature signal and compares it with the sampled signal. The compensation calculation module is used to calculate the compensation coefficient based on the deviation and output the correction signal; The signal conversion module is used to convert the corrected analog signal into a digital signal and input it to the controller. The data logging and alarm module is used to store temperature curves and trigger alarms when limits are exceeded.

[0010] More preferably, the temperature acquisition module includes multiple thermocouples or thermistor arrays. By deploying multiple thermocouples or thermistor arrays in the temperature acquisition module, multi-point synchronous temperature monitoring can be achieved at different key parts of the wind turbine. Thermocouples have the characteristics of wide range and fast response, and are suitable for high-temperature parts (such as gearbox oil sump and generator end cover); thermistors have high sensitivity and good stability, and are suitable for medium and low temperature parts (such as main shaft bearing and nacelle environment). When the two are arranged in a hybrid array, the most suitable type of sensing element can be selected according to the characteristics of the components, thereby improving the overall temperature measurement response speed and accuracy.

[0011] More preferably, the calibration reference module includes a reference temperature chip and a constant temperature control device. The calibration reference module is equipped with a reference temperature chip and a constant temperature control device, which can provide a stable and accurate standard temperature signal. The reference temperature chip serves as an internal reference source and outputs a constant temperature-voltage curve with an error controllable within ±0.05℃. The constant temperature control device maintains the chip at a constant operating temperature through temperature sensing feedback and a PID temperature stabilization circuit. When the wind turbine is operating in extremely cold or high temperature environments, it can still output a reference signal that is not affected by external factors, providing a reliable comparison standard for system calibration.

[0012] In a further preferred embodiment, the compensation calculation module employs a piecewise correction model to improve compensation accuracy. The compensation calculation module uses a piecewise correction model to correct the temperature signal, that is, based on the nonlinear drift characteristics of the sensor, the temperature range is divided into several intervals (e.g., −20~0℃, 0~40℃, 40~80℃), and correction coefficients K1, K2, K3, etc. are set in each interval. The piecewise correction method can better fit the drift curve of the sensor in different temperature intervals than a single linear model, and can keep the error minimized throughout the entire working range.

[0013] The embodiments of the present invention have the following advantages due to the adoption of the above technical solutions: I. This invention forms an independent calibration loop by setting up a reference temperature unit and a compensation calculation module in the acquisition system. While acquiring the temperature signal, the system reads the standard temperature signal in real time and calculates the deviation. Then, it performs linear or piecewise correction compensation based on the deviation, which can effectively offset the measurement errors caused by changes in ambient temperature, aging, or wire resistance drift of thermocouples or thermistors, so that the output temperature value is always consistent with the actual temperature.

[0014] Second, this invention, through a loop calibration mechanism and a constant temperature reference structure, enables the system to automatically perform reference calibration during unit startup or shutdown intervals. The reference temperature unit has a built-in constant temperature control device, which can maintain the stability of the output signal even when the external temperature changes significantly, ensuring that the calibration reference is not affected by the environment. After calibration, the updated compensation coefficient is automatically written into the controller storage unit for temperature correction in subsequent operating cycles, avoiding the problem of measurement reference drift caused by long-term continuous operation, ensuring the long-term stability and traceability of temperature monitoring data, reducing the frequency of manual calibration and maintenance, and improving the safety level of unit operation.

[0015] The above overview is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the invention will become readily apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a system module diagram of the present invention; Figure 2 This is a flowchart of the steps of the present invention. Detailed Implementation

[0018] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0019] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0020] like Figure 1 As shown in the figure, this embodiment of the invention provides a wind turbine operating temperature monitoring system, including: a temperature acquisition module, a calibration reference module, a compensation calculation module, a signal conversion module, and a data recording and alarm module.

[0021] The temperature acquisition module is installed in key heat-generating parts of the wind turbine, including the generator stator end cover, gearbox housing, main shaft bearing housing, and the internal environment of the nacelle. Each measuring point is equipped with a thermocouple or thermistor sensor and is connected to the acquisition port through a shielded signal line.

[0022] The calibration reference module is located inside the control cabinet and contains a reference temperature unit. This temperature unit includes a high-stability temperature chip and a constant temperature control device, which can maintain the stability of the output reference signal under different ambient temperatures. It is electrically connected to the acquisition module through a reference line and is used for comparison and calibration before unit startup or during operation intervals.

[0023] The compensation calculation module is located in the control unit. It is used to receive the real-time temperature signal output by the acquisition module and the standard signal provided by the reference module, calculate the deviation value ΔT between the two, and generate the compensation coefficient K according to the linear or piecewise correction model to correct the input signal.

[0024] The signal conversion module uses an analog-to-digital converter (A / D) chip to convert the compensated analog signal into a digital signal and transmit it to the main controller. This signal conversion module has a multi-channel input function and can process signals from multiple measurement points simultaneously, with a conversion accuracy better than 0.1℃.

[0025] The data recording and alarm module includes a storage unit, a display unit, and an alarm unit. The storage unit is used to save real-time temperature curves and historical data; the display unit can display the temperature of each measuring point on the monitoring screen; and the alarm unit drives an audible and visual alarm or sends an alarm signal to the upper-level monitoring system via a relay.

[0026] This system communicates with the unit's main control system via industrial Ethernet or CAN bus to form a continuous and reliable temperature monitoring closed loop.

[0027] like Figure 2 As shown, a method for monitoring the operating temperature of a wind turbine includes the following steps: S1. Temperature Acquisition Preparation and Signal Input Several temperature sensors are arranged at key components of the wind turbine generator stator, gearbox housing, main shaft bearing housing, and nacelle environment. The sensors can be thermocouples or thermistors, and their two ends are respectively connected to the input interface of the acquisition module.

[0028] When the unit is running, the sensor outputs a corresponding analog voltage signal based on the temperature change of the surface of the measured component. The amplitude of the voltage signal is proportional to the temperature of the measuring point. After each sensor signal enters the acquisition module, it is temporarily stored in the input buffer channel and the interference spike signal is initially eliminated by the hardware filtering circuit to form a continuous and stable analog input waveform.

[0029] S2. Signal Acquisition and Filtering After receiving analog signals from different measurement points, the acquisition module performs unified amplification and low-pass filtering through its internal signal conditioning circuit. During this process, the acquisition module first performs signal amplitude detection to prevent abnormal voltage input, and then uses a resistor-capacitor (RC) filter circuit to remove 50Hz interference and high-frequency noise. The filtered analog signal then enters the module's temporary buffer.

[0030] At the end of the filtering process, the system will synchronize the time of the signals acquired from each channel to ensure that the temperature data from different locations within the same time period remain consistent.

[0031] S3, Reference Loop Calibration This invention sets up a reference temperature unit and constructs a loop calibration channel to eliminate zero-point drift and gain error of the sensor caused by environmental changes. At system-defined time intervals (such as every 100 hours of operation or before each unit startup), the controller sends a calibration command to the calibration reference module. The module then activates its internal thermostat to heat or cool the reference unit to the standard temperature Tref (e.g., 25°C).

[0032] Simultaneously, the acquisition module reads the measured signal Tref_meas from the reference channel and compares it with the standard temperature Tref to obtain the deviation ΔT = Tref_meas − Tref. The deviation ΔT reflects the overall drift degree of the acquisition channel, and this deviation data will be transmitted to the compensation calculation module as a basis for correction.

[0033] S4. Temperature Drift Compensation Calculation and Signal Correction The compensation calculation module receives the temperature signal from the acquisition module and the deviation value ΔT from the calibration module, and calculates the correction coefficient K based on the built-in compensation model.

[0034] If a linear correction model is used, the compensation process is as follows: Trepair = Tmeasurement − K ×ΔT Wherein, K is the temperature drift coefficient, which can be set through equipment factory calibration or on-site experience.

[0035] If a piecewise correction model is used, different K values ​​are set in different temperature ranges (e.g., −20~0℃, 0~40℃, 40~80℃) to adapt to nonlinear drift characteristics.

[0036] After the compensation calculation is completed, the module outputs the corrected temperature signal T_corrected in real time to ensure that the measured temperature value is consistent with the actual temperature. If ΔT exceeds the allowable range (e.g., ±1℃), the system will mark the channel as "maintenance required" and prompt the maintenance personnel to replace or re-inspect the sensor.

[0037] S5, Analog-to-Digital Conversion and Data Upload The corrected analog temperature signal is digitized by the A / D conversion chip of the signal conversion module.

[0038] The chip converts the input voltage signal into a digital quantity at a preset sampling frequency (such as 10Hz) and outputs it to the main controller in a fixed byte format. The controller identifies the channel and packages the received digital signal, writes it into the system register, and updates the temperature curve on the display screen synchronously.

[0039] S6: Data logging, threshold determination, and alarm response The main controller periodically reads digital temperature data from the signal conversion module and stores it in the internal non-volatile memory. At the same time, it performs threshold judgment. When the temperature at any monitoring point exceeds the set upper limit Tmax or falls below the lower limit Tmin, the controller immediately sends a signal to the alarm module to drive the audible and visual alarm to sound an alarm and records the alarm channel number, alarm time and temperature value to the alarm log.

[0040] If the temperature returns to a safe range, the system automatically resets the alarm status. During normal operation of the unit, the system refreshes the data at a set period (e.g., 1 second) and displays the curves of each measuring point in real time. In the shutdown state, the controller triggers a complete loop calibration process, updates the compensation coefficient K and stores it in the EEPROM memory to provide accuracy guarantee for the next operating cycle.

[0041] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in the present invention, and these should all be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A wind turbine generator operating temperature monitoring method, characterized by, The method comprises the following steps: S1, installing temperature sensors at the generator, gear box, main shaft bearing and cabin environment of the wind turbine generator for collecting temperature signals; S2, transmitting the analog signals output by the temperature sensors to the collection module and performing filtering processing; S3, obtaining standard temperature signals by referring to the temperature unit and comparing the collected signals to obtain deviation values; S4, calculating compensation coefficients according to the deviation values and performing temperature drift compensation on the collected signals; S5, converting the corrected signals into digital signals by the analog-digital conversion module and inputting the digital signals into the controller; S6, generating alarm signals and recording temperature curves according to the set temperature range by the controller.

2. A wind turbine operating temperature monitoring method according to claim 1, wherein, The reference temperature unit adopts a constant temperature structure to keep the output signals stable.

3. A method of operating temperature monitoring of a wind turbine generator according to claim 1, wherein, The temperature drift compensation calculates the signal deviation by a linear correction model.

4. A method of operating temperature monitoring of a wind turbine generator according to claim 1, wherein, The signals are uploaded to the main control unit after A / D conversion for display and recording.

5. A method of operating temperature monitoring of a wind turbine generator according to claim 1, wherein, The system performs loop calibration once during the start-up or stoppage gap period of the unit.

6. A wind turbine operating temperature monitoring system according to any of claims 1-5, wherein, It comprises: a temperature collection module for collecting temperature signals of key parts of the unit; a calibration reference module for providing standard temperature signals and comparing the collected signals; a compensation calculation module for calculating compensation coefficients according to the deviation and outputting corrected signals; a signal conversion module for converting the corrected analog signals into digital signals and inputting the digital signals into the controller; a data recording and alarm module for storing temperature curves and triggering alarms when the limit is exceeded.

7. The wind turbine operating temperature monitoring system of claim 6, wherein, The temperature collection module comprises a plurality of thermocouple or thermistor arrays.

8. The wind turbine operating temperature monitoring system of claim 6, wherein, The calibration reference module comprises a reference temperature chip and a constant temperature control device.

9. The wind turbine operating temperature monitoring system of claim 6, wherein, The compensation calculation module adopts a segmented correction model to improve the compensation accuracy.

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