Wind turbine intelligent commissioning test system and test method

Abstract

The application discloses a kind of wind generating set intelligent joint commissioning test system and test method, test system is by fan processor, hub processor, communication system, data storage and console constitute, system control and detect fan each component sensor data, judge its performance reliability, finally generate result report, store into database, establish fan digital file;Test control system and unit data transmission protocol TCP / IP, control system passes through output operating system instruction, controls unit equipment action and collects sensor data and system data and carries out comparison judgment, finally generates unit test report.The application improves the test efficiency and quality of wind generating set before delivery, guarantees the high efficiency and accuracy of wind generating set delivery test, guarantees the effective authenticity of test record, is favorable to wind power generating set product digitization, is convenient for tracking and management to wind power generating set, so as to be favorable to realizing the production cycle digitization of wind power generating set.

Description

Technical Field

[0001] This invention relates to the field of wind power generation technology, specifically to an intelligent joint commissioning and testing system and method for wind turbine generator sets. Background Technology

[0002] Wind energy, as a clean and renewable energy source with a large total energy storage capacity, is becoming a new benchmark for clean energy. In recent years, wind turbine technology has matured, and wind turbines have become one of the most mature clean and renewable energy power generation technologies besides hydropower, with their share in the power industry increasing year by year. Currently, the production and assembly of wind turbines is becoming increasingly intelligent. After production and assembly, the assembly process and quality need to be verified to ensure the overall performance of the product. The verification process mainly verifies the mechanical and electrical properties of the assembled components to guarantee product quality. Summary of the Invention

[0003] In order to overcome the shortcomings of the existing technology, the present invention provides an intelligent commissioning and testing system and method for wind turbine generator sets.

[0004] This invention is achieved through the following technical solution: an intelligent commissioning and testing system for wind turbine generator sets, comprising a wind turbine processor, a hub processor, a communication system, a data storage device, and a control console. The system controls and detects sensor data from various components of the wind turbine, determines the reliability of its performance, and ultimately generates a result report, stores it in a database, and establishes a digital archive of the wind turbine. The testing system includes a test control system and a TCP / IP data transmission protocol for the generator set. The control system outputs operating system commands to control the actions of the generator set equipment and collects sensor data and system data for comparison and judgment, ultimately generating a generator set test report.

[0005] The unit test report includes the test time, unit number, base ambient temperature, base ambient humidity, unit insulation data, system equipment start-up and shutdown time, system equipment operating status, system equipment sensor data, faulty equipment alarm type, fault handling time, fault level, and sensor data after fault recovery.

[0006] The test console allows access to multiple wind turbine generators, automatically assigns unit numbers to these generators, and enables simultaneous intelligent joint commissioning tests on multiple units. It analyzes the test data of each wind turbine generator, generates a one-to-one test report, ensures the accuracy and real-time nature of the data, and ultimately forms a wind turbine generator database. This facilitates the full lifecycle management and data analysis of wind turbine generators from assembly to completion, as well as the management of turbine performance parameters and unit upgrades across various platforms.

[0007] The intelligent joint commissioning and testing control system mainly consists of an operation console, a control system processor, a memory, and a sensor system. The sensor system includes wireless transmission sensors for the test system and sensors for the main wind turbine system.

[0008] The control console enables human-machine interaction, data query, and instruction adjustment. The control system processor enables intelligent test data processing. Through a series of switch and analog signals from the equipment, the system analyzes the equipment's operating status.

[0009] The sensor system of the intelligent joint commissioning and testing control system includes wireless transmission sensors and various sensor signals of temperature, pressure, flow, differential pressure and liquid level of the wind turbine itself, forming a complete data monitoring system. The control system comprehensively analyzes the equipment operation status through feedback signals from various types of sensors to determine whether various equipment meet the wind turbine inspection and testing requirements. The memory will realize the storage of wind turbine data and form a database.

[0010] The control system enables one-button start-up and automatic sequencing of intelligent joint debugging tests. When a fault is encountered, the fault type is determined based on sensor parameters and component characteristics, and a clear fault type prompt is provided to facilitate fault diagnosis and handling. After the fault is resolved, the joint debugging test sequence can be resumed through the reset function to achieve a complete testing and verification process. Finally, a test report is generated and archived according to the unit number. The final test report cannot be modified. When it is necessary to access the test file, it can be retrieved or backed up through the console interface.

[0011] The main components of a doubly-fed wind turbine generator set include the generator, gearbox, main shaft, hub, and hydraulic station. The intelligent commissioning and testing control system meets the intelligent commissioning and testing requirements of all wind turbine generator sets through customized services. It adjusts and upgrades the relevant components of the generator, gearbox, main shaft, hub, and hydraulic station for different platform models, and supports the upgrade of unit functions.

[0012] This invention also discloses a testing method for an intelligent commissioning and testing system for wind turbine generator sets, which specifically includes the following steps:

[0013] (1) The operator selects the model to be debugged through the control system and starts the intelligent joint debugging test process, and the system enters the joint debugging test process;

[0014] (2) First, the system will determine whether the insulation of the engine room electrical system and the pitch electrical system meets the requirements. If it does not meet the requirements, it will indicate the fault type as insulation abnormality. If it meets the requirements, it will proceed to the next step.

[0015] (3) Safety system judgment: The system judges whether the safety system meets the requirements. If it does not meet the requirements, it will indicate the fault type as a safety system fault and enter the system test waiting stage until the fault is eliminated and the safety system alarm is cleared. If it meets the requirements, it will enter the equipment test stage.

[0016] (4) During the equipment testing phase, the system will issue equipment action commands. After the commands are output, the system will determine whether the equipment is normal or not based on the equipment action feedback and the sensor data of relevant components.

[0017] (5) If the system determines that the equipment is abnormal after comprehensive analysis, it will determine the fault type based on the actual sensor parameters and indicate the possible fault types. The system will determine whether to continue testing or switch to the test waiting state according to the priority. After the fault is handled, the system will repeat the fault command to determine whether it meets the test requirements. If yes, it will enter the next process. If no, it will continue this step and continue to wait.

[0018] (6) If the equipment is found to be operating normally after comprehensive analysis, the system will automatically proceed to the next test process;

[0019] (7) After all test steps are completed, the system will generate a report based on the real-time parameters.

[0020] After the gearbox oil pump motor starts, the instantaneous starting current, operating current, and three-phase voltage of the oil pump are monitored by the wireless power metering module. The flow rate and oil viscosity are monitored by the flow meter. The pump outlet pressure, return oil pressure, oil filter differential pressure, and oil sump temperature are monitored by the sensors built into the fan gearbox components. The system comprehensively monitors and judges whether the state of the oil pump in the initial stage of startup and after stable operation meets the fan quality inspection standards. If there is a fault, the system will issue an alarm and indicate the possible causes of the fault. For example, if the oil pump outlet and return oil pressure is abnormal, the system will prompt the operator that the oil pump is at risk of reverse rotation after analyzing all the data.

[0021] The beneficial effects of this invention are as follows: This invention aims to develop an intelligent commissioning and testing system for wind turbine generator sets, improving the efficiency and quality of pre-shipment testing of wind turbine generator sets, ensuring the efficiency and accuracy of factory testing, and guaranteeing the validity, authenticity, and traceability of test records. It is an intelligent commissioning and testing system that ensures production and assembly quality throughout the product lifecycle and facilitates after-sales service tracking. This invention aims to improve the quality and efficiency of wind turbine generator set commissioning and testing through a systematic testing scheme, realizing intelligent factory testing of wind turbine generator sets, accelerating the digitalization of the entire wind turbine generator set production cycle, and facilitating data traceability and the establishment of personalized wind turbine archives throughout the entire lifecycle. This invention utilizes simulated generator set operation to verify the quality of the assembly process, providing a reasonable and efficient inspection method. This invention controls various components and sensors of the generator set through a control system to perform propeller opening, feathering, wind patrol, yaw, and fault simulation. The technical solution in this invention can solve the problem of commissioning and testing after the completion of wind turbine generator set production and assembly. It facilitates the digitalization of wind turbine generator set products, making it easier to track and manage wind turbine generator sets, thereby contributing to the digitalization of the wind turbine generator set production cycle. Attached Figure Description

[0022] Figure 1 This is a network topology diagram of the intelligent joint commissioning and testing system for wind turbine generator sets of the present invention;

[0023] Figure 2 This is a schematic diagram of the control structure of the intelligent joint debugging and testing system of the present invention;

[0024] Figure 3 This is the control flowchart of the intelligent joint debugging and testing system of the present invention. Detailed Implementation

[0025] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0026] like Figure 1 As shown, the intelligent integrated commissioning and testing system for wind turbine generators in this invention consists of a wind turbine processor, a hub processor, a communication system, a data storage device, and a control console. The system controls and detects sensor data from various components of the wind turbine, determines the reliability of its performance, and ultimately generates a result report, stores it in a database, and establishes a digital archive of the wind turbine. The testing system includes a test control system and a TCP / IP data transmission protocol for the generator set. The control system outputs operating system commands to control the actions of the generator set equipment and collects sensor data, compares it with system data, and ultimately generates a generator set test report.

[0027] The report includes test time, unit number, base ambient temperature, base ambient humidity, unit insulation data, system equipment start-up and shutdown time, system equipment operating status, system equipment sensor data, faulty equipment alarm type, fault handling time, fault level, and sensor data after fault recovery.

[0028] The test console allows connection to multiple wind turbine generators, automatically assigns unit numbers to these units, and enables simultaneous intelligent joint commissioning tests across multiple units. It analyzes test data from each wind turbine generator and generates a unique test report. This ensures data accuracy and real-time performance, ultimately forming a wind turbine database. This facilitates full lifecycle management and data analysis of wind turbine generators from assembly to completion, and is beneficial for managing turbine performance parameters and upgrading units across various platforms.

[0029] The intelligent joint debugging and testing control system in this invention mainly consists of an operation console, a control system processor, a memory, and a sensor system. The sensor system includes wireless transmission sensors for the testing system and sensors for the main wind turbine system.

[0030] The control console enables human-machine interaction, data querying, and command adjustment. The control system processor performs intelligent test data processing, analyzing the equipment's operating status through a series of digital and analog signals.

[0031] The sensor system of the intelligent joint commissioning and testing control system includes wireless transmission sensors and various sensor signals from the wind turbine itself, such as temperature, pressure, flow, differential pressure, and liquid level, forming a complete data monitoring system. The control system comprehensively analyzes the equipment operation status through feedback signals from various types of sensors to determine whether various equipment meet the wind turbine inspection and testing requirements; the memory will realize the storage of wind turbine data and form a database.

[0032] For example, after the gearbox oil pump motor starts, the instantaneous starting current, operating current, and three-phase voltage of the oil pump are monitored by a wireless power metering module, while the flow rate and oil viscosity are monitored by a flow meter. Sensors integrated into the fan gearbox components monitor the pump outlet pressure, return oil pressure, filter differential pressure, and oil sump temperature. The system comprehensively monitors and determines whether the oil pump's initial startup state and its stable operation meet the fan's quality inspection standards. If a fault is detected, the system issues an alarm and indicates possible causes, such as abnormal oil pump outlet and return pressure. After analyzing all data, the system will alert the operator that the oil pump may be at risk of reverse rotation.

[0033] In addition, the control system can be started with a single button, enabling automatic sequencing of intelligent joint debugging tests. When a fault is encountered, the system determines the fault type based on sensor parameters and component characteristics, and provides clear fault type prompts to facilitate troubleshooting and handling. After fault handling is completed, the joint debugging test sequence can be resumed via the reset function to achieve a complete testing and verification process. A test report is then generated and archived according to the unit number. The final test report cannot be modified. When test files need to be accessed, they can be retrieved or backed up via the console interface.

[0034] The main components of a doubly-fed wind turbine generator set currently include the generator, gearbox, main shaft, hub, and hydraulic station.

[0035] The intelligent commissioning and testing control system can meet the intelligent commissioning and testing requirements of all wind turbine models through customized services. It can be adjusted and upgraded for the testing needs of related components such as generators, gearboxes, main shafts, hubs, and hydraulic stations of different platform models, and supports the upgrading of unit functions.

[0036] Based on the different types of wind turbine generators, such as doubly fed, direct-drive, and semi-direct-drive, and the different testing requirements of the generators themselves, the testing procedures can be differentiated.

[0037] like Figure 2 and Figure 3 As shown, the test method of the intelligent commissioning and testing system for wind turbine generator sets of the present invention is as follows:

[0038] (1) The operator selects the model to be debugged through the control system and starts the intelligent joint debugging test process. The system enters the joint debugging test process.

[0039] (2) First, the system will determine whether the insulation of the engine room electrical system and the pitch electrical system meets the requirements. If it does not meet the requirements, it will prompt the fault type "insulation abnormality". If it meets the requirements, it will proceed to the next step.

[0040] (3) Safety system judgment: The system judges whether the safety system meets the requirements. If it does not meet the requirements, it will prompt the fault type "safety system fault" and enter the system test waiting stage until the fault is eliminated and the safety system alarm is cleared. If it meets the requirements, it will enter the equipment test stage.

[0041] (4) During the equipment testing phase, the system will issue equipment action commands. After the commands are output, the system will determine whether the equipment is normal or not based on the equipment action feedback and the sensor data of relevant components.

[0042] (5) If the system determines that the equipment is abnormal after comprehensive analysis, it will determine the fault type based on the actual sensor parameters and indicate the possible fault types. The system will determine whether to continue testing or switch to the test waiting state according to the priority. After the fault is handled, the system will repeat the fault command to determine whether it meets the test requirements. If yes, it will enter the next process. If no, it will continue this step and continue to wait.

[0043] (6) If the equipment is operating normally after comprehensive analysis, the system will automatically enter the next test process.

[0044] (7) After all test steps are completed, the system will generate a report based on the real-time parameters.

[0045] 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 test method for an intelligent commissioning and testing system for wind turbine generator sets, characterized in that: An intelligent integrated commissioning and testing system for wind turbine generators was adopted. This system consists of a wind turbine processor, a hub processor, a communication system, a data storage device, and a control console. The system controls and detects sensor data from various components of the wind turbine, determines the reliability of its performance, and finally generates a result report, stores it in a database, and establishes a digital archive of the wind turbine. The testing system includes a test control system and a TCP / IP data transmission protocol for the generator set. The control system controls the actions of the generator set equipment by outputting operating system commands and collects sensor data and compares it with system data to make judgments, ultimately generating a generator set test report. The test console allows access to multiple wind turbine generators, automatically assigns unit numbers to multiple wind turbine generators, and enables simultaneous intelligent joint commissioning tests of multiple units. It analyzes the test data of each wind turbine generator, generates a one-to-one test report, ensures the accuracy and real-time nature of the data, and ultimately forms a wind turbine generator database. The testing method of the intelligent commissioning and testing system for wind turbine generator sets specifically includes the following steps: (1) The operator selects the model to be debugged through the control system and starts the intelligent joint debugging test process, and the system enters the joint debugging test process; (2) First, the system determines whether the insulation of the engine room electrical system and the pitch electrical system meets the requirements. If it does not meet the requirements, it will indicate the fault type as insulation abnormality. If it meets the requirements, it will proceed to the next step. (3) Safety system judgment: The system judges whether the safety system meets the requirements. If it does not meet the requirements, it will indicate the fault type as a safety system fault and enter the system test waiting stage until the fault is eliminated and the safety system alarm is cleared. If it meets the requirements, it will enter the equipment test stage. (4) Equipment testing phase: The system issues equipment action commands. After the commands are output, the system determines whether the equipment is normal or not based on the equipment action feedback and the sensor data of relevant components. (5) After comprehensive analysis, if the system determines that the equipment is abnormal, it will determine the fault type based on the actual sensor parameters and indicate the possible fault types. The system will determine whether to continue testing or switch to test waiting state based on priority. Once the fault handling is complete, the system repeats the fault command to determine if the test requirements are met. If yes, proceed to the next step; otherwise, continue this step and wait. (6) After comprehensive analysis, if the equipment is operating normally, the system will automatically proceed to the next test process; (7) After all test steps are completed, the system generates a report based on real-time parameters; After the gearbox oil pump motor starts, the instantaneous starting current, operating current, and three-phase voltage of the oil pump are monitored by the wireless power metering module. The flow rate and oil viscosity are monitored by the flow meter. The pump outlet pressure, return oil pressure, oil filter differential pressure, and oil sump temperature are monitored by the sensors built into the fan gearbox components. The system comprehensively monitors and judges whether the state of the oil pump in the initial stage of startup and after stable operation meets the fan quality inspection standards. If there is a fault, the system issues an alarm and indicates the possible causes of the fault. For example, if the oil pump outlet and return oil pressure is abnormal, after analyzing all the data, the system will prompt the operator that the oil pump is at risk of reverse rotation. The control system can be started with one click, realizing intelligent joint commissioning and automatic testing steps. When a fault point is encountered, the fault type is determined based on sensor parameters and component characteristics, and there is a clear fault type prompt. After the fault is handled, the joint commissioning and testing steps can continue through the reset step function. Finally, a test report is generated and archived according to the unit number. The final test report cannot be modified. When it is necessary to call the test file, it can be retrieved or backed up through the console interface.

2. The test method of the intelligent commissioning and testing system for wind turbine generator sets according to claim 1, characterized in that: The unit test report includes the test time, unit number, basic ambient temperature, basic ambient humidity, unit insulation data, system equipment start-up and shutdown time, system equipment operating status, system equipment sensor data, fault equipment alarm type, fault handling time, fault level, and sensor data after fault recovery.

3. The test method of the intelligent joint commissioning and testing system for wind turbine generator sets according to claim 1, characterized in that: The intelligent joint commissioning and testing control system mainly consists of an operation console, a control system processor, a memory, and a sensor system. The sensor system includes wireless transmission sensors for the test system and sensors for the main wind turbine system.

4. The test method of the intelligent commissioning and testing system for wind turbine generator sets according to claim 3, characterized in that: The control console enables human-machine interaction, data query, and instruction adjustment. The control system processor enables intelligent test data processing. Through a series of switch and analog signals from the equipment, the system analyzes the equipment's operating status.

5. The test method of the intelligent commissioning and testing system for wind turbine generator sets according to claim 1, characterized in that: The sensor system of the intelligent joint commissioning and testing control system includes wireless transmission sensors and various sensor signals of temperature, pressure, flow, differential pressure and liquid level of the wind turbine itself, forming a complete data monitoring system. The control system comprehensively analyzes the equipment operation status through feedback signals from various types of sensors, determines whether various equipment meet the wind turbine inspection and testing requirements, and realizes wind turbine data storage in the memory to form a database.

6. The test method of the intelligent commissioning and testing system for wind turbine generator sets according to claim 1, characterized in that: The main components of a doubly-fed wind turbine generator set include the generator, gearbox, main shaft, hub, and hydraulic power unit. The intelligent commissioning and testing control system is adjusted and upgraded to meet the testing requirements of the generator, gearbox, main shaft, hub, and hydraulic power unit components of different platform models, and supports the functional upgrade of the unit.

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