Intelligent locking system and method for wind turbine impeller

Abstract

The application discloses a kind of wind generator impeller intelligent locking system and method, wherein system includes: set in the hydraulic locking pin of cabin;With nine-hole type rotor locking disc connected with impeller;High-speed shaft disc motor turning system is used to complete motor turning;Mobile RFID system is used to detect and identify different pin hole positions;PLC control system is used to control hydraulic locking pin, high-speed shaft disc motor turning system, mobile RFID system work and identify different signals fed back by mobile RFID system.Recognition unit of mobile RFID system automatically detects and identifies different transponders, identifies pin hole position signal, and feeds back signal to PLC control system, and PLC control system controls high-speed disc motor turning system, and high-speed shaft disc carries out turning action, and PLC control system controls hydraulic locking pin to extend or retract, to realize the locking or release of impeller.The application can realize the directional locking of impeller by single person quickly.

Description

Technical Field

[0001] This invention relates to the field of wind turbine technology, specifically to a smart locking system and method for wind turbine rotors. Background Technology

[0002] Currently, the conventional impeller locking principle in the wind power industry is as follows: The system is stopped via PLC, the blades are aligned with the propeller until the impeller stops rotating, and the relative positions of the multi-hole rotor locking disc pin holes connected to the impeller and the mechanical locking pins located in the nacelle are observed. The impeller is manually rotated (by turning the high-speed output shaft of the drive chain to rotate the impeller), and the positions of the rotor locking disc pin holes and locking pins are continuously observed until they are nearly aligned. The hydraulic braking system is then immediately activated to brake the rotation system. At this point, it is checked whether the rotor locking disc pin holes and locking pins are completely axially aligned. If they are not aligned, the braking system needs to be released and the rotor rotation continued for adjustment. Once the braked rotor locking disc pin holes and locking pins are axially aligned again, the locking pins are manually pushed into the corresponding pin holes of the rotor locking disc, thus completing the impeller locking.

[0003] Existing impeller locking systems require manual rotation, which is time-consuming and labor-intensive. Depending on the gearbox's transmission ratio, the impeller typically requires approximately 150 revolutions to complete one full rotation at high speed. To achieve specific blade positions, multiple people often need to take turns rotating the impeller, resulting in significant physical exertion and low efficiency. Existing impeller locking systems require coordinated operation from multiple personnel to lock the impeller. This means that while personnel are rotating the impeller, another person must specifically observe the alignment of the locking pin with the rotor locking disc's pin hole, and yet another person must be dedicated to controlling the PLC to be ready to activate the hydraulic braking system. The existing impeller locking system has a low success rate on the first attempt. The hydraulic braking system requires a certain response and action time to activate. During rotation, the observer needs to anticipate the alignment of the locking pin and pin hole at the current impeller rotation speed and notify the PLC controller in advance to activate the hydraulic braking system, allowing sufficient response and action time. However, often after the braking system activates, the locking pin and pin hole positions are not perfectly aligned axially, requiring further fine-tuning, significantly increasing labor intensity and reducing work efficiency.

[0004] Therefore, there is an urgent need in the existing technology for a wind turbine rotor intelligent locking system that can enable a single person to quickly lock the rotor in a directional manner, with high work efficiency, low labor consumption, and low labor intensity. Summary of the Invention

[0005] The primary objective of this invention is to overcome the shortcomings of existing technologies and provide an intelligent wind turbine rotor locking system that enables rapid directional locking of the rotor by a single person and improves working efficiency.

[0006] The first objective of this invention is achieved through the following technical solution: an intelligent locking system for wind turbine rotors, comprising:

[0007] Hydraulic locking pins installed in the engine room;

[0008] Corresponding to the nine-hole rotor locking disc that connects the hydraulic locking pin to the impeller, the nine-hole rotor locking disc is concentric with the impeller;

[0009] High-speed shaft code disk electric trolley system, used to complete electric trolley operation;

[0010] Mobile RFID system for detecting and identifying the positions of different pin holes;

[0011] The PLC control system is used to control the operation of the hydraulic locking pin, the high-speed shaft code disk electric turning system, the mobile RFID system, and to identify different signals fed back by the mobile RFID system.

[0012] The nine-hole rotor locking disc is connected to the impeller to achieve synchronous rotation with the impeller. The impeller is locked by the hydraulic locking pin, which passes through the pin hole of the nine-hole rotor locking disc.

[0013] The PLC control system controls the hydraulic locking pins, extending or retracting them to lock or release the impeller. It also controls the high-speed encoder electric turning system, enabling the turning action of the high-speed encoder. Furthermore, the PLC control system can control the mobile RFID system, starting and stopping it, and identifying different signals and operating durations from the mobile RFID system.

[0014] The nine-hole rotor locking disc includes a locking disc body, a shaft hole formed in the center of the locking disc body, connecting holes evenly arranged around the shaft hole on the disc surface of the locking disc body, and three pin hole groups evenly arranged on the outer side of the connecting holes on the disc surface of the locking disc body.

[0015] Each of the pin hole groups consists of three pin holes, the center of which lies on a circle centered on the impeller center.

[0016] In a pin hole group, the angle between the center of two adjacent pin holes and the center of the impeller is 30°.

[0017] The mobile RFID system includes an identification unit, nine transponders, and a control system. The identification unit is installed inside the cabin, and the transponders are installed on the nine-hole rotor locking disc, with each of the nine transponders corresponding to one of the nine pin holes.

[0018] The mobile RFID system is connected to the PLC control system via a CANOPEN interface.

[0019] The identification unit is an RFID sensor, and the transponder is the object of identification by the identification unit. This RFID system is equipped with a total of 9 transponders. The 9 pin hole positions identified by the identification unit correspond to the distribution posture of the three blades under 9 different impeller locking conditions. Through system settings, the RFID system can automatically detect and identify different transponders, thereby feeding back signals to the PLC control system.

[0020] The high-speed shaft code disk electric turning system includes a turning motor, a drive gear connected to the power output end of the turning motor, and a high-speed shaft code disk meshing with the drive gear. The high-speed shaft code disk drives the impeller to rotate through a gearbox.

[0021] The high-speed shaft code disk electric turning system drives the high-speed shaft code disk through a turning motor, thereby rotating the high-speed shaft. The high-speed shaft drives the impeller to rotate through a gearbox, realizing electric turning. The turning motor and the high-speed shaft code disk are transmitted through gear meshing. After the speed ratio is converted by the gearbox, the turning motor rotates at high speed, while the impeller rotates at low speed, which can ensure the accuracy of the rotor locking pin hole position on the impeller when the electric turning is stopped.

[0022] The hydraulic locking pin includes a hydraulic cylinder and a pin connected to the piston rod of the hydraulic cylinder. The hydraulic cylinder is connected to a hydraulic station via a pipeline. The hydraulic locking pin is pushed by the pressure provided by the hydraulic station to extend and retract, replacing the traditional manual push-in and pull-back locking pin. The pin extends and passes into the pin hole of the nine-hole rotor locking disc to lock the impeller. The locking pin is located on the nacelle at the 6 o'clock position corresponding to the impeller.

[0023] The second objective of this invention is to overcome the shortcomings of the existing technology and provide a smart locking method for wind turbine rotors that enables a single person to quickly and directionally lock the rotor, resulting in higher working efficiency.

[0024] The second objective of this invention is achieved through the following technical solution: a method for intelligent locking of a wind turbine rotor, comprising the following: a hydraulic locking pin is installed in the nacelle; a nine-hole rotor locking disc is installed on the rotor corresponding to the hydraulic locking pin; the nine-hole rotor locking disc is concentric with the rotor and rotates synchronously with the rotor; a mobile RFID system is installed, comprising an identification unit, a transponder, and a control system; the identification unit is installed in the nacelle; the transponder is installed on the nine-hole rotor locking disc; the identification unit automatically detects and identifies different transponders; the identification pin hole position signal is detected and fed back to the PLC control system; the PLC control system controls a high-speed encoder electric cheering system; the high-speed encoder performs cheering action; and the PLC control system controls the hydraulic locking pin to extend or retract, thereby locking or releasing the rotor.

[0025] The nine-hole rotor locking disc has a shaft hole formed in the center of the locking disc body. The disc surface of the locking disc body has connecting holes evenly arranged around the shaft hole. Three pin hole groups are evenly arranged on the outer side of the connecting holes on the disc surface of the locking disc body. Each pin hole group consists of three pin holes. The center of the pin holes is on a circle with the impeller center as the center. In a pin hole group, the angle between the center of two adjacent pin holes and the impeller center is 30°. The mobile RFID system is equipped with 9 transponders, which correspond to 9 pin hole positions. The 9 pin hole positions identified by the identification unit correspond to the different distribution postures of the three blades under 9 impeller locking conditions.

[0026] The beneficial effects of this invention are: this invention enables a single person to quickly lock the impeller in a directional manner, which improves work efficiency, liberates labor, and enhances the intelligence level of wind turbines. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a nine-hole rotor locking disc;

[0028] Figure 2 This is a schematic diagram of the impeller structure.

[0029] In the diagram: 1-First blade; 2-Second blade; 3-Third blade; A1-Pin hole No. 1 (Group 1); A2-Pin hole No. 2 (Group 1); A3-Pin hole No. 3 (Group 1); B1-Pin hole No. 1 (Group 2); B2-Pin hole No. 2 (Group 2); B3-Pin hole No. 3 (Group 2); C1-Pin hole No. 1 (Group 3); C2-Pin hole No. 2 (Group 3); C3-Pin hole No. 3 (Group 3). Detailed Implementation

[0030] The present invention will now be described in detail with reference to the accompanying drawings.

[0031] See Figure 1 , Figure 2 The impeller includes a first blade 1, a second blade 2, and a third blade 3. The nine-hole rotor locking disc includes a set of first pin holes A1, a set of second pin holes A2, a set of third pin holes A3, two sets of first pin holes B1, two sets of second pin holes B2, two sets of third pin holes B3, three sets of first pin holes C1, three sets of second pin holes C2, and three sets of third pin holes C3.

[0032] The nine pin holes of the nine-hole rotor locking disc are distributed as follows: the angle formed by the center of pin hole A1 and the center of impeller is 30° with the center of pin hole A2 and the center of impeller; the angle formed by the center of pin hole A2 and the center of pin hole A3 and the center of impeller is 30° with the center of pin hole A3 and the center of pin hole A3. The pin holes B and C are arrayed in the circumferential direction to form the nine-hole rotor locking disc. Each pin hole locks a different distribution posture of the three blades A, B, and C. The pin shaft is located on the nacelle at the 6 o'clock position corresponding to the impeller.

[0033] This invention enables rapid, single-person directional locking of the impeller, improving work efficiency and the level of intelligence in wind turbines. While ensuring rapid impeller locking, this invention designs a lightweight, hydraulic locking pin and high-speed shaft code disk electric trolley system to replace traditional manual operation, freeing up labor and increasing work efficiency. The application of a mobile RFID system in wind turbines is an industry first, and its perfect integration with the wind turbine's PLC control system realizes an intelligent impeller locking process.

[0034] Example 1

[0035] As required for work, personnel wish to enter the interior of the first blade 1 for inspection and maintenance. Before doing so, the first blade 1 needs to be adjusted to a horizontal position and the impeller locked. After the wind turbine stops, the RFID system starts working, recording the position range of the three blades after the impeller stops. At this time, the wind turbine PLC control system selects the distribution posture of the three blades after the impeller is locked. Depending on the work requirements, the first blade 1 is selected to be at the horizontal position of 3 o'clock or 9 o'clock, for example, the 3 o'clock position. The RFID system feeds back the current position information of the three blades to the wind turbine PLC control system. After receiving the information, the PLC control system selects the shortest working time scheme based on the pre-recorded signal switching time between each transponder of the RFID system, i.e., forward or reverse rotation. The PLC control system sends forward or reverse rotation commands to the high-speed shaft code disk electric turning system. The high-speed shaft code disk electric turning system then engages and begins turning, causing the impeller to rotate. When the two sets of pin holes B1 on the rotor locking disk of the impeller rotate to the 6 o'clock position, the transponders corresponding to the two sets of pin holes B1 coincide with the identification unit. The RFID system sends a feedback signal to the wind turbine PLC control system, which then sends a command to the high-speed shaft code disk electric turning system to stop turning. At this point, the two sets of pin holes B1 on the rotor locking disk are axially aligned with the pins on the nacelle. After turning stops, the PLC control system sends a command to the hydraulic locking pin to extend the pin shaft, locking the impeller. At this time, the first blade 1 is in the horizontal 3 o'clock position, allowing personnel to enter the first blade 1 for inspection and maintenance. After the work is completed, the PLC control system is operated to cancel the impeller locking, the hydraulic locking pin retracts, and the turning system exits the system operation.

[0036] Example 2

[0037] As required by the work, the staff intends to perform external inspection and maintenance on the first blade 1. Before this, the first blade 1 needs to be adjusted to a vertical 6 o'clock position and the impeller locked. After the wind turbine stops, the RFID system starts working and records the position range of the three blades after the impeller stops. At this time, the wind turbine PLC control system selects that the first blade 1 is in a vertical 6 o'clock position after the impeller is locked. The RFID system feeds back the current position information of the three blades to the wind turbine PLC control system. After receiving the information, the PLC control system selects the shortest working time scheme based on the pre-entered signal switching time between each transponder of the RFID system, i.e., forward or reverse rotation. The PLC control system sends forward or reverse rotation commands to the high-speed shaft code plate electric turning system. The high-speed shaft code plate electric turning system then engages and begins turning, causing the impeller to rotate. When a set of pin holes A2 on the rotor locking plate rotates to the 6 o'clock position, the transponder corresponding to pin hole A2 aligns with the identification unit. The RFID system sends a feedback signal to the wind turbine PLC control system, which then sends a command to the high-speed shaft code plate electric turning system to stop turning. At this point, a set of pin holes A2 on the rotor locking plate axially aligns with the pin shaft on the nacelle. After turning stops, the PLC control system sends a command to the hydraulic locking pin to extend the pin shaft, locking the impeller. At this time, the first blade 1 is in the vertical 6 o'clock position, allowing personnel to access the outside of the first blade 1 via a suspended platform for inspection and maintenance. After the work is completed, the PLC control system is operated to cancel the impeller locking, the hydraulic locking pin retracts, and the turning system exits the system operation.

[0038] Example 3

[0039] As required by the work, if staff wish to perform internal inspection and maintenance on the impeller without entering the blades, they only need to lock the impeller beforehand. After the wind turbine stops, the RFID system starts working, recording the position range of the three blades after the impeller stops. At this time, the wind turbine PLC control system selects free locking, and the RFID system feeds back the current position information of the three blades to the wind turbine PLC control system. After receiving the information, the PLC control system selects the shortest working time scheme based on the pre-recorded signal switching working time between each transponder of the RFID system, i.e., selecting the transponder closest to the 6 o'clock position. The PLC control system sends a forward or reverse rotation command to the high-speed shaft code disk electric turning system, which starts turning. The impeller begins to rotate. When the nearest pin hole on the rotor locking disk of the impeller rotates to the 6 o'clock position, the transponder corresponding to the pin hole coincides with the identification unit. The RFID system feeds back a signal to the wind turbine PLC control system, and the PLC control system sends a command to the high-speed shaft code disk electric turning system to stop turning. At this time, the pin hole on the rotor locking disk axially coincides with the pin shaft on the nacelle. After the impeller stops rotating, the PLC control system sends a command to extend the hydraulic locking pin. The hydraulic locking pin then extends to lock the impeller.

[0040] Finally, it should be noted that the above content is only used to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Simple modifications or equivalent substitutions made by those skilled in the art to the technical solution of the present invention do not depart from the essence and scope of the technical solution of the present invention.

Claims

1. A smart locking system for wind turbine rotors, characterized in that: The intelligent locking system for wind turbine rotors includes: Hydraulic locking pins installed in the engine room; Corresponding to the nine-hole rotor locking disc that connects the hydraulic locking pin to the impeller, the nine-hole rotor locking disc is concentric with the impeller; High-speed shaft code disk electric trolley system, used to complete electric trolley operation; Mobile RFID system for detecting and identifying the positions of different pin holes; The PLC control system is used to control the operation of the hydraulic locking pin, the high-speed shaft code disk electric trolley system, the mobile RFID system, and to identify different signals fed back by the mobile RFID system. The nine-hole rotor locking disc includes a locking disc body, a shaft hole formed in the center of the locking disc body, connecting holes evenly arranged around the shaft hole on the disc surface of the locking disc body, and three pin hole groups evenly arranged on the outer side of the connecting holes on the disc surface of the locking disc body. Each of the pin hole groups consists of three pin holes, with the center of each pin hole on a circle centered on the impeller center. In a pin hole group, the angle between the center of two adjacent pin holes and the center of the impeller is 30°; The mobile RFID system includes an identification unit, nine transponders, and a control system. The identification unit is installed inside the cabin, and the transponders are installed on the nine-hole rotor locking disc, with each of the nine transponders corresponding to one of the nine pin holes.

2. The intelligent locking system for wind turbine rotors according to claim 1, characterized in that: The mobile RFID system is connected to the PLC control system via a CANOPEN interface.

3. The intelligent locking system for wind turbine rotors according to claim 1, characterized in that: The high-speed shaft code disk electric turning system includes a turning motor, a drive gear connected to the power output end of the turning motor, and a high-speed shaft code disk meshing with the drive gear. The high-speed shaft code disk drives the impeller to rotate through a gearbox.

4. The intelligent locking system for wind turbine rotors according to claim 1, characterized in that: The hydraulic locking pin includes a hydraulic cylinder and a pin connected to the piston rod of the hydraulic cylinder. The hydraulic cylinder is connected to a hydraulic station via a pipeline.

5. A method for intelligent locking of a wind turbine rotor, characterized in that... The system includes the following: a hydraulic locking pin is installed in the nacelle; a nine-hole rotor locking disc is installed on the impeller corresponding to the hydraulic locking pin; the nine-hole rotor locking disc is concentric with the impeller and rotates synchronously with the impeller; a mobile RFID system is installed, which includes an identification unit, a transponder, and a control system; the identification unit is installed in the nacelle; the transponder is installed on the nine-hole rotor locking disc; the identification unit automatically detects and identifies different transponders; the identification pin hole position signal is detected and the signal is fed back to the PLC control system; the PLC control system controls the high-speed encoder electric trolley system; the high-speed encoder performs trolley action; and the PLC control system controls the hydraulic locking pin to extend or retract, thereby locking or releasing the impeller. The nine-hole rotor locking disc has a shaft hole formed in the center of the locking disc body. The disc surface of the locking disc body has connecting holes evenly arranged around the shaft hole. Three pin hole groups are evenly arranged on the outer side of the connecting holes on the disc surface of the locking disc body. Each pin hole group consists of three pin holes. The center of the pin holes is on a circle with the impeller center as the center. In a pin hole group, the angle between the center of two adjacent pin holes and the impeller center is 30°. The mobile RFID system is equipped with 9 transponders, which correspond to 9 pin hole positions. The 9 pin hole positions identified by the identification unit correspond to the different distribution postures of the three blades under 9 impeller locking conditions.

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