A wind turbine gearbox flexible pin deformation variable measurement device and method

Abstract

The present invention discloses a device and method for measuring the deformation variable of a flexible pin of a wind turbine gearbox, comprising a control box and a bracket, wherein the control box is connected to a plurality of sensors; the bracket comprises a first bracket mounted on a base and a second bracket arranged near the end of a hydraulic cylinder; the bottom end of the first bracket is fastened to the base, the middle section is parallel to the axis direction of a pin shaft sleeve, and the top end is bent toward the end of the pin shaft sleeve; at least one sensor is installed at the bottom end, the middle section, and the top end of the first bracket; at least two sensors are installed on the second bracket; the detection head of the sensor contacts the outer wall of the pin shaft sleeve or the hydraulic cylinder; a data acquisition mechanism is arranged in the control box and connected to a host computer. The present invention includes a complete signal detection, transmission, data collection, and data analysis system, which is easy to deploy and convenient for further monitoring the status of the target device to be measured through program software, unified export and import of measurement data, and recording of measurement curve changes.

Description

Technical Field

[0001] The invention relates to the field of detection and measurement, and in particular to a device and method for measuring the deformation amount of a flexible pin shaft of a gear box of a wind power generation equipment. Background Art

[0002] The flexible pin is one of the key core components of the wind turbine gearbox. During the operation of the wind turbine gearbox, in order to avoid the bending of the ordinary pin under stress and affecting the gear meshing, the pin of the wind turbine gearbox adopts a flexible pin, so that the flexible pin is subjected to the balancing force of the bearing and does not deform during the operation. However, due to the inevitable errors in processing, manufacturing, positioning, and installation, the theoretically calculated flexible pin is often subjected to unbalanced forces, causing the flexible pin to deform like an ordinary pin, thereby affecting the gear meshing and damaging the wind turbine gearbox. In severe cases, it may even cause the wind turbine gearbox to be interrupted and scrapped.

[0003] Currently, it is impossible to obtain the actual balance point of the flexible pin through theoretical calculation. The only way is to simulate the force on the flexible pin in the wind turbine gearbox to observe the deformation degree of the flexible pin and reversely infer its theoretical balance point based on the actual situation.

[0004] In response to the above problems, considering that the load borne by the flexible pin is small and the deformation is small, an electrical solution is designed to measure the flexible pin deformation variables, collect data parameters, and at the same time improve the safety and reliability of the designed product. Summary of the invention

[0005] The present invention is to solve the above-mentioned problem and proposes a device and method for measuring the deformation variable of a flexible pin of a wind turbine gearbox.

[0006] The present invention is achieved according to the following technical contents.

[0007] A device for measuring the deformation variable of a flexible pin of a wind turbine gearbox, wherein the flexible pin is installed on a base, a pin shaft sleeve is nested outside the flexible pin, the pin shaft sleeve passes through the base and is perpendicular to the base, and a hydraulic cylinder is also provided on the base to apply external force to the flexible pin; the device is characterized in that the measuring device comprises a control box and a bracket, the control box is connected to a plurality of sensors, and the sensors are all connected to the control box via a first cable; the bracket comprises a planetary carrier installed above the base, and a first bracket and a second bracket are provided on the planetary carrier; the bottom end of the first bracket is fastened to the planetary carrier, the middle section is parallel to the axial direction of the pin shaft sleeve, and the top end is bent toward the end of the pin shaft sleeve. ; At least one sensor is installed at the bottom, middle and top of the first bracket, wherein the measuring head of the sensor deployed at the bottom points to the surface of the base, the measuring head of the sensor deployed in the middle points to the side wall of the pin sleeve, and the measuring head of the sensor deployed at the top points to the end of the pin; the second bracket is deployed close to the end of the hydraulic cylinder, and includes a support part and a crossbeam, the crossbeam is parallel to the end of the hydraulic cylinder, and at least two sensors are installed on the crossbeam; the detection head of the sensor contacts the outer wall of the pin sleeve or the hydraulic cylinder; a data acquisition mechanism is provided in the control box, and the data acquisition mechanism is connected to the host computer through a second cable.

[0008] Furthermore, the data acquisition mechanism includes a communication module, a host, and multiple slaves; the host and the slave are respectively connected to a sensor via a first cable; the host and the slave are also connected to each other in series via a control interface, and their tail ends are connected to the communication module; the communication module is connected to a host computer via a second cable.

[0009] Furthermore, the sensor model is HG-S1110; the host model is HG-SC101; the slave model is HG-SC111; and the communication module model is SC-HG1-485.

[0010] Furthermore, the host computer is a PC, which has an RS485 interface card integrated therein; the second cable is a twisted pair cable, and the second cable is connected to the RS485 interface card.

[0011] Furthermore, the number of sensors installed on the middle section of the first bracket is five, and they are arranged at equal intervals along the axis direction of the pin shaft sleeve.

[0012] Furthermore, a power supply module and an environmental monitoring module are also provided in the control box; the input end of the power supply module is connected to the AC power supply input from the outside of the control box; the first output end of the power supply module is short-circuited with the input end, and a step-down module is provided inside the power supply module to adjust the input end voltage to DC24V and output it from the second output end; the second output end is connected to the environmental monitoring module and the data acquisition mechanism.

[0013] Furthermore, the environmental monitoring module is provided with an illumination lamp, a cooling fan, and a temperature and humidity controller; a controllable switch of the temperature and humidity controller is connected in series to a power supply circuit of the cooling fan.

[0014] Furthermore, a control socket and a sensor fixing bracket are provided in the control box; the control socket is connected to the first output terminal of the power module.

[0015] Furthermore, the model of the temperature and humidity controller is THC031.

[0016] A method for measuring the deformation variable of a flexible pin of a wind turbine gearbox, wherein the host computer receives signals from each sub-machine and obtains real-time measurement values ​​of each sensor therefrom, wherein each sensor is set with an independent channel number, and the measurement values ​​of each channel are collected at the same time point, and each channel is repeatedly collected according to an inherent sampling frequency, and the collected data are stored in a non-volatile storage area of ​​the host computer; a database is established; and based on the database, the following processing is performed:

[0017] (1) Display the database in a table format on the host computer;

[0018] (2) Using time as a reference, draw a curve of the real-time measurement value of each channel in a dot-plotting manner and display it on the host computer;

[0019] (3) Within a set time period, the real-time measurement values ​​of one or more channels are averaged and summed, and the calculation results are displayed on the host computer.

[0020] The present invention is used for collecting data on the deformation of the axis of the bearing surface of a gear flexible pin in a wind turbine gearbox. Sensors are respectively arranged on the flexible pin, the base and the hydraulic cylinder for displacement monitoring. The real-time data measured by all sensors are summarized, analyzed and calculated to determine whether the deformation exceeds the standard.

[0021] The advantages and beneficial effects of the present invention are:

[0022] The present invention obtains the law of the deformation displacement of the axle pin through a micro-deformation collection and processing method, and realizes the control of the entire system through a control box. It includes a control panel, an indicator light, a control loop, etc., and cyclically communicates the measured values ​​according to a high-speed sampling cycle, and transmits them to the host device in a high-precision data state, with an accuracy level of up to 1μm. At the same time, the device is suitable for impact-resistant environments, and the measurement results are highly reliable. The host, sub-machine, communication module and host computer form a complete signal detection, transmission, data collection, and data analysis system, which is easy to deploy and convenient for further monitoring the status of the target device to be measured through program software, unified export and import of measurement data, and recording of measurement curve changes. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 Schematic diagram of the installation position of the sensor and the first bracket in the present invention;

[0024] Figure 2 Schematic diagram of the installation position of the sensor and the second bracket in the present invention;

[0025] Figure 3 A top view of the present invention;

[0026] Figure 4 is a structural block diagram of the measuring device in the present invention;

[0027] Figure 5 This is a circuit diagram of the functional modules such as lighting, heat dissipation and sockets in the present invention;

[0028] Figure 6 is a circuit diagram of a temperature control circuit in the present invention;

[0029] Figure 7 It is a circuit diagram of the power module in the present invention.

[0030] Among them, 1. pin sleeve; 2. base; 3. first bracket; 4. sensor; 5. hydraulic cylinder; 6. second bracket; 7. planetary carrier. DETAILED DESCRIPTION

[0031] The present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0032] like Figures 1 to 7As shown, a device for measuring the deformation variable of a flexible pin of a wind turbine gearbox is provided, wherein the flexible pin is installed on a base 2, a pin shaft sleeve 1 is nested outside the flexible pin, the pin shaft sleeve 1 passes through the base 2 and is perpendicular to the base 2, and a hydraulic cylinder 5 is also provided on the base 2 to apply an external force to the flexible pin; it is characterized in that the measuring device comprises a control box and a bracket, the control box is connected to a plurality of sensors 4, and the sensors 4 are all connected to the control box through a first cable; the bracket comprises a planetary carrier 7 installed above the base 2, and a first bracket 3 and a second bracket 6 are provided on the planetary carrier 7; the bottom end of the first bracket 3 is fastened to the planetary carrier 7, the middle section is parallel to the axial direction of the pin shaft sleeve 1, and the top end is toward the pin shaft sleeve 1 The end is bent; at least one sensor 4 is installed at the bottom, middle and top of the first bracket 3, wherein the measuring head of the sensor 4 deployed at the bottom points to the surface of the base 2, the measuring head of the sensor 4 deployed in the middle points to the side wall of the pin sleeve 1, and the measuring head of the sensor 4 deployed at the top points to the end of the pin; the second bracket 6 is deployed near the end of the hydraulic cylinder 5, including a support part and a crossbeam, the crossbeam is parallel to the end of the hydraulic cylinder 5, and at least two sensors 4 are installed on the crossbeam; the detection head of the sensor 4 contacts the outer wall of the pin sleeve 1 or the hydraulic cylinder 5; a data acquisition mechanism is provided in the control box, and the data acquisition mechanism is connected to the host computer through a second cable. When the sensor 4 is installed and used, in order to meet the measurement progress requirements, the sensor detection head is kept perpendicular to the target device to be measured and contacts the surface of the target device to be measured. This paragraph mentions the specific forms of the planetary frame 7, the first bracket 3, and the second bracket 6, and it is not necessary to design them completely in this way. The planetary carrier 7 is fixed to the base 2 by screws. The function of the first bracket 3 and the second bracket 6 is to install the sensor 4. The side wall of the pin shaft and the end of the pin shaft are the locations where the sensor 4 must be deployed. In addition, the sensor 4 also needs to be deployed between the bracket and the base 2. This is mainly to consider the simultaneous monitoring of the deformation of the base 2 during the measurement process, to realize data collection, the influence of the flexible pin deformation and to provide reference data.

[0033] The data acquisition mechanism includes a communication module, a host, and multiple slaves; the host and the slave are respectively connected to a sensor 4 through a first cable; the host and the slave are also connected in series with each other through a control interface, and their tail ends are connected to the communication module; the communication module is connected to the host computer through a second cable.

[0034] The sensor 4 is of model HG-S1110, a contact digital displacement sensor produced by Panasonic, with a full range measurement accuracy of less than 1.0 μm and a narrow range measurement accuracy of less than 0.5 μm (any 60 μm). The host is of model HG-SC101 and the slave is of model HG-SC111, both designed and manufactured by Panasonic, and can be used in conjunction with the sensor 4; the communication module is of model SC-HG1-485. The first cable is a special cable for the above components, which can be used to transmit signals (from the sensor to the host or slave) and electric energy (from the host or slave to the sensor).

[0035] The host computer is a PC, which has an RS485 interface card integrated inside; the second cable is a twisted pair cable, and the second cable is connected to the RS485 interface card. The host computer reads the data from each sensor through the interface card, and uniformly summarizes, analyzes and stores the data. With the powerful processing power of the host computer, once the detected data exceeds the standard value, the operator can quickly discover it.

[0036] The number of sensors 4 installed on the middle section of the first bracket 3 is five, and they are arranged at equal intervals along the axis direction of the pin sleeve 1. The distance between each two sensors is 100-200mm. The sensors are evenly distributed, and the displacement of the flexible pin under different pressures is measured to obtain the corresponding deformation law.

[0037] The control box is also provided with a power supply module and an environmental monitoring module; the input end of the power supply module is connected to the AC power supply input from the outside of the control box; the first output end of the power supply module is short-circuited with the input end, and a step-down module is provided inside the power supply module to adjust the input end voltage to DC24V and output it from the second output end; the second output end is connected to the environmental monitoring module and the data acquisition mechanism.

[0038] The environment monitoring module is provided with an illumination lamp, a cooling fan, and a temperature and humidity controller; a controllable switch of the temperature and humidity controller is connected in series in the power supply circuit of the cooling fan.

[0039] A control socket and a sensor fixing bracket are arranged in the control box; the control socket is connected to the first output end of the power module.

[0040] The external input power is AC230V, which is short-circuited to the first output terminal; Figure 5 and Figure 6 As shown:

[0041] The first output terminal supplies power to the lighting circuit, which includes an air switch 6F1, a terminal X22, a travel switch 6S1, and a lighting lamp 6E1 connected in series via a cable.

[0042] The first output terminal also supplies power to the cooling fan circuit, which includes an air switch 6F2, a cooling fan 6M2, and a controllable switch in the temperature and humidity controller connected in series through a cable. Figure 5 The arrow in the middle indicates the position, access Figure 6 COM2 and NO2 are contacts in the middle; COM2 and NO2 are the normally open contacts of the controllable switch. This controllable switch is connected in series in the cooling fan circuit to control the start and stop of the fan.

[0043] The first output terminal also supplies power to the control socket circuit, which includes an air switch 6F3 and a control socket 6X4 connected in series via a cable.

[0044] The second output terminal of the power module outputs a DC24V power supply.

[0045] The second output terminal is connected to the temperature and humidity controller through the air switch 6F5. The controllable switch linkage mechanism in the temperature and humidity controller is set as follows: the cooling fan setting value is 35℃, and the temperature hysteresis is 5℃. In this way, when t≥35℃, the normally open contact of the controllable switch is closed, and the cooling fan starts; when t≤30℃, the normally open contact of the controllable switch is disconnected, and the cooling fan stops.

[0046] A method for measuring the deformation variable of a flexible pin of a wind turbine gearbox, wherein the host computer receives signals from each sub-machine and obtains real-time measurement values ​​of each sensor therefrom, wherein each sensor is set with an independent channel number, and the measurement values ​​of each channel are collected at the same time point, and each channel is repeatedly collected according to an inherent sampling frequency, and the collected data are stored in a non-volatile storage area of ​​the host computer; a database is established; and based on the database, the following processing is performed:

[0047] (1) Display the database in a table format on the host computer;

[0048] (2) Using time as a reference, draw a curve of the real-time measurement value of each channel in a dot-plotting manner and display it on the host computer;

[0049] (3) Within a set time period, the real-time measurement values ​​of one or more channels are averaged and summed, and the calculation results are displayed on the host computer.

[0050] The method and principle of use of the present invention are:

[0051] First, the sensor 4 is installed on the first bracket 3 and the second bracket 6. The first bracket 3 and the second bracket 6 are installed on the planet carrier, and the sensor 4 is aligned with the pin by fine-tuning the positions of the first bracket 3 and the second bracket 6.

[0052] The power module converts the external 230V AC power supply into DC24V, and supplies power to the host, slave, communication module, temperature and humidity controller, etc. The host and slave supply power to the sensor 4 through the first cable. After the sensor is installed, it will no longer move. If the surface of the target device to be measured is deformed, such as the pin sleeve 1, the side head of the sensor will be squeezed or separated from the surface of the target device to be measured. Although this deformation is often small, the measuring head of the sensor 4 can sense the displacement change of 1μm, and the measurement accuracy is very high.

[0053] The device can be configured with a host and multiple slaves, and each slave or a combination of the host and the sensor serves as a measurement channel. The total number of measurement channels is determined according to actual needs, but during use, the number of measurement channels will be redundant, so that some measurement channels are idle. Although they are also deployed in the control box, they are not powered and are only used as backup. Since the sensor 4 and the slave are both high-precision devices, they cannot be placed at will, so a dedicated equipment bracket is set in the control box to place the backup sensor.

[0054] After the device is powered on, the host and slave collect the real-time values ​​measured by the sensor and send them to the host computer through the communication module, thereby realizing real-time monitoring of the target device under test. When installed for the first time, the detection head of sensor 4 contacts the target device under test, and the PC clears the corresponding measurement value. After that, if the reading on a certain measurement channel deviates from the 0 value and exceeds the threshold range, the reading of the channel is considered abnormal. If the reading of sensor 4 contacting the same surface of the same target device fluctuates regularly, the host computer can also identify it as soon as possible through statistical calculation and analysis, thereby providing reliable data reference for the measurement operator.

Claims

1. A device for measuring deformation of a flexible pin of a wind turbine gearbox, wherein the flexible pin is mounted on a base (2), a pin shaft sleeve (1) is nested outside the flexible pin, the pin shaft sleeve (1) passes through the base (2) and is perpendicular to the base (2), and a hydraulic cylinder (5) for applying external force to the flexible pin is also provided on the base (2); the device is characterized in that: The measuring device comprises a control box and a bracket, wherein the control box is connected to a plurality of sensors (4), and the sensors (4) are all connected to the control box via a first cable; the bracket comprises a planetary frame (7) mounted above the base (2), and the planetary frame (7) is provided with a first bracket (3) and a second bracket (6); the bottom end of the first bracket (3) is fastened to the planetary frame (7), the middle section is parallel to the axis direction of the pin shaft sleeve (1), and the top end is bent toward the end of the pin shaft sleeve (1); at least one sensor (4) is installed at the bottom end, the middle section, and the top end of the first bracket (3), wherein the sensor (4) deployed at the bottom end The measuring head of the sensor (4) is directed toward the surface of the base (2), the measuring head of the sensor (4) deployed in the middle section is directed toward the side wall of the pin shaft sleeve (1), and the measuring head of the sensor (4) deployed at the top end is directed toward the end of the pin shaft; the second bracket (6) is deployed near the end of the hydraulic cylinder (5), and comprises a support portion and a crossbeam, the crossbeam is parallel to the end of the hydraulic cylinder (5), and no less than two sensors (4) are mounted on the crossbeam; the detection head of the sensor (4) contacts the outer wall of the pin shaft sleeve (1) or the hydraulic cylinder (5); a data acquisition mechanism is provided in the control box, and the data acquisition mechanism is connected to the host computer via a second cable; The data acquisition mechanism comprises a communication module, a host, and a plurality of slaves; the host and the slave are respectively connected to a sensor (4) via a first cable; the host and the slave are also connected in series via a control interface, the tail ends of which are connected to the communication module; the communication module is connected to a host computer via a second cable; The control box is also provided with a power supply module and an environmental monitoring module; the input end of the power supply module is connected to the AC power supply input from the outside of the control box; the first output end of the power supply module is short-circuited with the input end, and a step-down module is provided inside the power supply module to adjust the input end voltage to DC24V and output it from the second output end; the second output end is connected to the environmental monitoring module and the data acquisition mechanism.

2. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 1, characterized in that: The sensor (4) is of model HG-S1110; the host is of model HG-SC101; the slave is of model HG-SC111; and the communication module is of model SC-HG1-485.

3. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 1, characterized in that: The host computer is a PC, which has an RS485 interface card integrated therein; the second cable is a twisted pair cable, and the second cable is connected to the RS485 interface card.

4. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 1, characterized in that: The number of sensors (4) installed on the middle section of the first bracket (3) is five, and they are arranged at equal intervals along the axis direction of the pin shaft sleeve (1).

5. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 1, characterized in that: The environment monitoring module is provided with an illumination lamp, a cooling fan, and a temperature and humidity controller; a controllable switch of the temperature and humidity controller is connected in series in the power supply circuit of the cooling fan.

6. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 1, characterized in that: A control socket and a sensor fixing bracket are arranged in the control box; the control socket is connected to the first output end of the power module.

7. A wind turbine gearbox flexible pin deformation variable measuring device as claimed in claim 5, characterized in that: The model of the temperature and humidity controller is THC031.

8. A method for measuring the deformation of a flexible pin of a wind turbine gearbox, characterized in that: The device for measuring the deformation variable of the flexible pin of the gearbox of a wind turbine generator according to any one of claims 1 to 7 is adopted, wherein the host computer receives the signals sent by each sub-machine and obtains the real-time measurement values ​​of each sensor therefrom, wherein each sensor is set with an independent channel number, and the measurement values ​​of each channel are collected at the same time point, and each channel is repeatedly collected according to the inherent sampling frequency, and the collected data is stored in the non-volatile storage area of ​​the host computer; a database is established; and based on the database, the following processing is performed: (1) Display the database in a table format on the host computer; (2) Using time as a reference, draw a curve of the real-time measurement value of each channel in a dot-plotting manner and display it on the host computer; (3) Within the set time period, the real-time measurement values ​​of one or more channels are averaged and summed, and the calculation results are displayed on the host computer.

Images