Equipment testing system and methods

Abstract

The present disclosure relates to a device detection system and method to improve the accuracy and reliability of fault detection of a target object. The system includes a vibration sensing unit, a signal detection unit, and a signal analysis terminal; the vibration sensing unit is used to convert the mechanical vibration of the target object into an electrical signal; the signal detection unit is used to identify the electrical signal to obtain N effective values ​​corresponding to N frequency bands; the signal detection unit is used to determine the state level of the target object based on the N effective values ​​when the Nth effective value corresponding to the Nth frequency band is greater than a preset signal threshold, and send the state level to the signal analysis terminal; the signal analysis terminal is used to determine the fault state detection result of the target object according to the state level.

Description

Technical Field

[0001] The present disclosure relates to the field of vibration detection equipment, and in particular, to an equipment detection system and method. Background Art

[0002] At present, there are two main methods for detecting the status of wind turbine transmission chain components, namely the threshold judgment method and the spectrum analysis method. Among them, the threshold judgment method mainly judges whether the effective value of vibration acceleration exceeds the limit based on industry standards, thereby determining the fault level of the unit's transmission chain components. The spectrum analysis method mainly relies on analysts to view the time domain waveform and spectrum diagram of the vibration signal to determine the fault level and fault location of the unit's transmission chain components.

[0003] However, since the vibration of wind turbines is greatly affected by the operating conditions of the units, the accuracy of the threshold judgment method is low, while the accuracy of the spectrum analysis method depends on the experience of the analysts and has low reliability. Summary of the invention

[0004] The purpose of the present disclosure is to provide a device detection system and method to solve the above technical problems.

[0005] In order to achieve the above-mentioned object, a first aspect of the present disclosure provides a device detection system, the system comprising a vibration sensing unit, a signal detection unit and a signal analysis terminal;

[0006] The vibration sensing unit is used to convert the mechanical vibration of the target object into an electrical signal;

[0007] The signal detection unit is used to identify the electrical signal to obtain N effective values ​​corresponding to N frequency bands, wherein the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1;

[0008] The signal detection unit is used to determine the state level of the target object based on the N valid values ​​when the N valid value corresponding to the N frequency band is greater than the preset signal threshold, and send the state level to the signal analysis terminal;

[0009] The signal analysis terminal is used to determine a fault state detection result of the target object according to the state level.

[0010] Optionally, the system further comprises an energy conversion unit and an energy collection unit;

[0011] The energy conversion unit is used to convert the mechanical vibration of the target object into electrical energy;

[0012] The energy collection unit is used to store the electric energy and supply power to the signal detection unit.

[0013] Optionally, the signal detection unit is further configured to determine, when the Nth effective value is less than or equal to the preset signal threshold, that the state level of the target object is a first level, wherein the first level indicates that no fault occurs to the target object.

[0014] Optionally, the N frequency bands are 4 frequency bands, and the N valid values ​​corresponding to the N frequency bands are respectively a first valid value corresponding to the first frequency band, a second valid value corresponding to the second frequency band, a third valid value corresponding to the third frequency band, and a fourth valid value corresponding to the fourth frequency band, and the signal detection unit is used to:

[0015] determining a first ratio of the first effective value to the fourth effective value, determining a second ratio of the second effective value to the fourth effective value, and determining a third ratio of the third effective value to the fourth effective value;

[0016] When the third ratio is greater than the first ratio and the third ratio is greater than the second ratio, determining that the state level of the target object is the second level;

[0017] When the second ratio is greater than the first ratio and the second ratio is greater than the third ratio, determining that the state level of the target object is the third level;

[0018] When the first ratio is greater than the second ratio and the first ratio is greater than the third ratio, determining that the state level of the target object is a fourth level;

[0019] The fault severity represented by the second level, the third level and the fourth level increases in sequence.

[0020] Optionally, the signal detection unit is further used to collect the vibration waveform data of the target object and send it to the signal analysis terminal when the Nth effective value is greater than a preset signal threshold;

[0021] The signal analysis terminal is also used to determine a fault location detection result of the target object based on the vibration waveform data.

[0022] Optionally, the signal analysis terminal is further used to send a detection instruction to the signal detection unit when the device group where the target object is located meets a preset detection start condition, and the preset detection start condition includes that during the first detection after the device group is started, the generator speed of the device group reaches the rated speed, or during a non-first detection after the device group is started, the generator speed of the device group reaches the rated speed, and the time interval from the last detection time is greater than or equal to the preset time interval;

[0023] The signal detection unit is further configured to identify the electrical signal in response to the detection instruction to obtain the N effective values ​​corresponding to the N frequency bands.

[0024] Optionally, the vibration sensing unit and the transducer unit are encapsulated in a first encapsulation component, the first encapsulation component is arranged at a preset detection point of the target object, the signal detection unit and the energy collection unit are encapsulated in a second encapsulation component, and the first encapsulation component and the second encapsulation component are connected via a cable;

[0025] The signal analysis terminal communicates with the second packaging component wirelessly, and is connected to a control cabinet of the equipment group where the target object is located through a cable, so as to obtain power supply and generator speed data.

[0026] A second aspect of the present disclosure further provides a device detection method, which is applied to a device detection system, wherein the system includes a vibration sensing unit, a signal detection unit, and a signal analysis terminal, and the method includes:

[0027] The vibration sensing unit converts the mechanical vibration of the target object into an electrical signal;

[0028] The signal detection unit identifies the electrical signal to obtain N effective values ​​corresponding to N frequency bands, wherein the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1;

[0029] The signal detection unit determines the state level of the target object based on the N valid values ​​when the N valid value corresponding to the N frequency band is greater than the preset signal threshold, and sends the state level to the signal analysis terminal;

[0030] The signal analysis terminal determines a fault state detection result of the target object according to the state level.

[0031] Optionally, the system further includes an energy conversion unit and an energy collection unit, and the method further includes:

[0032] The transducer unit converts mechanical vibration of the target object into electrical energy.

[0033] The energy collection unit stores the electric energy and supplies power to the signal detection unit.

[0034] Optionally, the method further comprises:

[0035] When the Nth effective value is less than or equal to the preset signal threshold, the signal detection unit determines that the state level of the target object is a first level, and the first level indicates that no fault occurs to the target object.

[0036] Optionally, the N frequency bands are 4 frequency bands, and the N valid values ​​corresponding to the N frequency bands are respectively a first valid value corresponding to the first frequency band, a second valid value corresponding to the second frequency band, a third valid value corresponding to the third frequency band, and a fourth valid value corresponding to the fourth frequency band, and determining the state level of the target object based on the N valid values ​​includes:

[0037] The signal detection unit determines a first ratio of the first effective value to the fourth effective value, determines a second ratio of the second effective value to the fourth effective value, and determines a third ratio of the third effective value to the fourth effective value;

[0038] The signal detection unit determines that the state level of the target object is the second level when the third ratio is greater than the first ratio and the third ratio is greater than the second ratio;

[0039] The signal detection unit determines that the state level of the target object is a third level when the second ratio is greater than the first ratio and the second ratio is greater than the third ratio;

[0040] The signal detection unit determines that the state level of the target object is a fourth level when the first ratio is greater than the second ratio and the first ratio is greater than the third ratio;

[0041] The fault severity represented by the second level, the third level and the fourth level increases in sequence.

[0042] Optionally, the method further comprises:

[0043] The signal detection unit collects the vibration waveform data of the target object and sends it to the signal analysis terminal when the Nth effective value is greater than a preset signal threshold;

[0044] The signal analysis terminal determines a fault location detection result of the target object based on the vibration waveform data.

[0045] Optionally, the method further comprises:

[0046] The signal analysis terminal sends a detection instruction to the signal detection unit when the device group where the target object is located meets the preset detection start condition, and the preset detection start condition includes that the generator speed of the device group reaches the rated speed during the first detection after the device group is started, or the generator speed of the device group reaches the rated speed during the non-first detection after the device group is started, and the time interval from the last detection time is greater than or equal to the preset time interval;

[0047] The signal detection unit identifies the electrical signal in response to the detection instruction to obtain the N effective values ​​corresponding to the N frequency bands.

[0048] In the above technical solution, the vibration sensing unit is used to convert the mechanical vibration of the target object into an electrical signal, and the signal detection unit is used to identify the electrical signal to obtain N effective values ​​corresponding to N frequency bands, and when the Nth effective value corresponding to the Nth frequency band is greater than the preset signal threshold, the state level of the target object is determined based on the N effective values, and the state level is sent to the signal analysis terminal, and the signal analysis terminal is used to determine the fault state detection result of the target object according to the state level. With this system, the fault state detection result is obtained by analyzing the effective values ​​of multiple vibration frequency bands of the target object, which can reduce the probability of misjudgment caused by occasional abnormal vibrations, and the detection result can be obtained without manual analysis, thereby improving the accuracy and reliability of fault detection of the target object and reducing labor costs.

[0049] Other features and advantages of the present disclosure will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The accompanying drawings are used to provide a further understanding of the present disclosure and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present disclosure but do not constitute a limitation of the present disclosure. In the accompanying drawings:

[0051] Figure 1 is a schematic diagram of a device detection system provided by an embodiment of the present disclosure;

[0052] Figure 2 is a schematic diagram of an installation of a device detection system provided by an embodiment of the present disclosure;

[0053] Figure 3 is a flow chart of a device detection method provided by an embodiment of the present disclosure;

[0054] Figure 4 is a schematic diagram of another device detection system shown in an embodiment of the present disclosure;

[0055] Figure 5 It is a schematic diagram of the logical processing of a device detection system shown in an embodiment of the present disclosure. DETAILED DESCRIPTION

[0056] The specific implementation of the present disclosure is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described herein is only used to illustrate and explain the present disclosure, and is not used to limit the present disclosure.

[0057] It should be understood that the various steps described in the method implementation of the present disclosure may be performed in different orders and / or in parallel. In addition, the method implementation may include additional steps and / or omit the steps shown. The scope of the present disclosure is not limited in this respect. The term "including" and its variations used herein are open inclusions, i.e., "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one other embodiment"; the term "some embodiments" means "at least some embodiments". The relevant definitions of other terms will be given in the description below.

[0058] It should be noted that the concepts of "first", "second", etc. mentioned in the present disclosure are only used to distinguish different devices, modules or units, and are not used to limit the order or interdependence of the functions performed by these devices, modules or units. It should be noted that the modifications of "one" and "multiple" mentioned in the present disclosure are illustrative rather than restrictive, and those skilled in the art should understand that unless otherwise clearly indicated in the context, they should be understood as "one or more".

[0059] At present, the downtime and maintenance costs caused by wind turbine transmission chain failures have always been an important part of the operation and maintenance costs of wind power operators. Effective detection of wind turbine transmission chains, timely discovery of potential failures of unit components, and preventive maintenance are important ways to reduce operation and maintenance costs. Due to the complex operating conditions of wind turbines, there are many types of transmission chain fault detection equipment, such as acoustic emission detectors, listening sticks, audio detectors, visual detectors, vibration test analyzers, etc.

[0060] Since mechanical equipment is always accompanied by mechanical vibration during operation, and when there is a fault in a component, the vibration signal will be abnormal, and a specific frequency component representing the fault will appear in the signal, making vibration detection one of the important means of detecting wind turbine transmission chain faults. At present, there are two main detection methods for the status of wind turbine transmission chain components, namely the threshold judgment method and the spectrum analysis method. Among them, the threshold judgment method mainly judges whether the effective value of the vibration acceleration exceeds the limit based on the industry standard, so as to determine the fault level of the unit transmission chain component. The spectrum analysis method mainly relies on analysts to view the time domain waveform and spectrum diagram of the vibration signal to determine the fault level and fault location of the unit transmission chain component. However, since the vibration size of the wind turbine is greatly affected by the operating conditions of the unit, the accuracy of the threshold judgment method is low, and the accuracy of the spectrum analysis method depends on the experience of the analyst, and the reliability is low.

[0061] In view of this, the present disclosure provides a device detection system and method to solve the above technical problems.

[0062] The present disclosure is described below in conjunction with specific embodiments.

[0063] Reference Figure 1 The present disclosure provides a device detection system, which includes a vibration sensing unit 101, a signal detection unit 102 and a signal analysis terminal 103. The vibration sensing unit 101 is used to convert the mechanical vibration of the target object into an electrical signal. The signal detection unit 102 is used to identify the electrical signal and obtain N valid values ​​corresponding to N frequency bands, wherein the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1. The signal detection unit 102 is used to determine the state level of the target object based on the N valid values ​​when the Nth valid value corresponding to the Nth frequency band is greater than a preset signal threshold, and send the state level to the signal analysis terminal. The signal analysis terminal 103 is used to determine the fault state detection result of the target object according to the state level.

[0064] For example, the Nth frequency band needs to include frequencies from the 1st frequency band to the N-1th frequency band. For example, the lower limit frequency of the 1st frequency band is 10Hz, the upper limit frequency of the N-1th frequency band is 5000Hz, and the Nth frequency band can be 10Hz to 5000Hz, or 5Hz-5005Hz, etc. The present disclosure is not limited to this, and it only needs to include frequencies from the 1st frequency band to the N-1th frequency band. Thus, the Nth effective value corresponding to the Nth frequency band can represent the overall vibration of the target object and be compared with the preset signal threshold to perform preliminary vibration detection on the target object. Among them, the Nth effective value greater than the preset signal threshold indicates that the target object has abnormal vibration, and the preset signal threshold can be set with reference to industry standards, and the present disclosure is not limited to this.

[0065] By adopting the above system, the fault status detection results are obtained by analyzing the effective values ​​of multiple vibration frequency bands of the target object, which can reduce the probability of misjudgment caused by occasional abnormal vibrations, and the detection results can be obtained without manual analysis, thereby improving the accuracy and reliability of fault detection of the target object and reducing labor costs.

[0066] It is worth noting that, at present, there are three types of vibration detection equipment for wind turbine transmission chain components, namely online vibration detection equipment, offline vibration detection equipment and wireless vibration detection equipment. Among them, the online vibration detection equipment consists of a fixed data acquisition terminal, a vibration sensor, and a sensor cable. The data acquisition terminal and the vibration sensor are installed and deployed when the unit is shut down. After the unit is running, vibration data collection can be carried out without the presence of personnel. The offline vibration detection equipment consists of a portable data acquisition terminal, a vibration sensor, and a sensor cable. When the wind turbine is running, the detection personnel need to perform manual operation in the cabin to carry out vibration data collection. The wireless vibration detection equipment combines wireless transmission technology with sensor technology. The wireless vibration detection equipment composed of a wireless vibration sensor and a data acquisition terminal omits the sensor cable and can meet the needs of offline vibration detection and continuous vibration detection for a certain period of time.

[0067] However, online vibration detection equipment has the disadvantages of complex system installation and long construction time. After the system is built, it has high requirements for network resources, server storage and computing resources. Offline vibration detection equipment also has problems such as personal safety hazards and high labor intensity of detection personnel. Although wireless vibration detection equipment reduces the difficulty of installation and deployment, due to the small space of wind turbines, wireless vibration sensors usually use an integrated design of vibration sensing elements, signal processing circuits, and power supply systems. They are large in size and have the disadvantage of being difficult to install at some measurement points. In addition, their battery life is limited and cannot meet the needs of long-term detection.

[0068] Therefore, in a possible manner, the system further comprises an energy conversion unit and an energy collection unit, wherein the energy conversion unit is used to convert the mechanical vibration of the target object into electrical energy, and the energy collection unit is used to store electrical energy and supply power to the signal detection unit.

[0069] For example, by converting the mechanical vibration of the target object into electrical energy for use by the signal detection unit, the signal detection unit does not need to rely on batteries for power supply, thereby saving energy and improving the endurance of the signal detection unit.

[0070] In a possible manner, the vibration sensing unit and the transducer unit are encapsulated in a first encapsulation component, the first encapsulation component is set at a preset detection point of the target object, the signal detection unit and the energy collection unit are encapsulated in a second encapsulation component, and the first encapsulation component and the second encapsulation component are connected by a cable. The signal analysis terminal communicates with the second encapsulation component wirelessly and is connected to a control cabinet of the equipment group where the target object is located by a cable to obtain power supply and generator speed data.

[0071] For example, refer to Figure 2 , the vibration sensing unit and the transducer unit are packaged and obtain the mechanical vibration of the target object at the preset detection point, and then the electrical signal converted from the mechanical vibration is transmitted to the signal detection unit through the cable, and the electrical energy converted from the mechanical vibration is transmitted to the energy collection unit through the cable, and finally the energy collection unit stores the electrical energy and supplies power to the signal detection unit, without relying on batteries for power supply, thereby improving the endurance of the signal detection unit. The signal analysis terminal communicates with the second packaging component wirelessly, without the need to lay cables, reducing the difficulty and time of installation. And the signal analysis terminal can be set near the control cabinet of the equipment group where the target object is located and connected by cables to obtain power supply and generator speed data. In addition, the signal analysis terminal can also be connected to the power supply system separately to obtain power supply, which is not limited in the present disclosure.

[0072] It should be noted that the vibration sensing unit and the transducer unit have simple structures and small volumes, and can be installed at detection points with narrow spaces. The signal detection unit and the energy collection unit can be set in a larger area near the detection point, and the first package component and the second package component are connected by a cable to meet the detection requirements of a small space and ensure the endurance of the signal detection unit.

[0073] In a possible manner, the signal detection unit is further configured to determine, when the Nth effective value is less than or equal to a preset signal threshold, that the state level of the target object is a first level, wherein the first level indicates that no fault occurs to the target object.

[0074] It should be noted that when there is a fault in the transmission chain component of the unit, the vibration signal becomes abnormal and a specific frequency component that characterizes the fault appears. Generally speaking, when the component fault is in the early stage, the energy proportion of the high-order harmonic component of the fault characteristic frequency is high. As the component fault develops, the energy proportion of the mid-order harmonic component of the fault characteristic frequency gradually increases. When the component fault develops to the later stage, the low-order harmonic component of the fault characteristic frequency becomes prominent.

[0075] Therefore, in a possible manner, the N frequency bands are 4 frequency bands, and the N effective values ​​corresponding to the N frequency bands are respectively the first effective value corresponding to the first frequency band, the second effective value corresponding to the second frequency band, the third effective value corresponding to the third frequency band, and the fourth effective value corresponding to the fourth frequency band, and the signal detection unit is used to: determine the first ratio of the first effective value to the fourth effective value, determine the second ratio of the second effective value to the fourth effective value, and determine the third ratio of the third effective value to the fourth effective value. In the case where the third ratio is greater than the first ratio and the third ratio is greater than the second ratio, the state level of the target object is determined to be the second level. In the case where the second ratio is greater than the first ratio and the second ratio is greater than the third ratio, the state level of the target object is determined to be the third level. In the case where the first ratio is greater than the second ratio and the first ratio is greater than the third ratio, the state level of the target object is determined to be the fourth level. Among them, the fault severity represented by the second level, the third level and the fourth level increases in sequence.

[0076] For example, different target objects and different measuring points of target objects have different fault characteristic frequencies, and the corresponding relationship between the fault characteristic frequencies and the degree of component fault development is also different. The fault characteristic frequencies of different measuring points and the corresponding relationship between the fault characteristic frequencies and the degree of component fault development can be sent to the signal detection unit by the signal analysis terminal before detection. Taking the measuring point deployed at the bearing seat of the generator drive end as an example, the frequency range corresponding to the first frequency band is 10Hz-300Hz, the frequency range corresponding to the second frequency band is 300Hz-1000Hz, the frequency range corresponding to the third frequency band is 1000Hz-5000Hz, and the frequency range corresponding to the fourth frequency band is 10Hz-5000Hz.

[0077] Furthermore, using a RMS 、b RMS 、c RMS d RMS , m represent the first effective value, the second effective value, the third effective value, the fourth effective value, and the preset signal threshold, respectively, then the first ratio is K a =a RMS / d RMS , the second ratio is K b =b RMS / d RMS , the third ratio is K c=c RMS / d RMS When d RMS Greater than m, and k c Greater than k a With k b When d RMS Greater than m, and k b Greater than k a With k c When d RMS Greater than m, and k a Greater than k b With k c , it is determined that the status level of the target object is the fourth level.

[0078] Among them, the first level indicates that the target object is in a normal operating state, the second level indicates that the target object is in the early stage of a fault, the third level indicates that the target object is in the middle stage of a fault, and the fourth level indicates that the target object is in the late stage of a fault. The signal analysis terminal determines the fault state detection result of the target object according to the state level, and can directly use the state level as the detection result, or use the fault state represented by the state level as the detection result, such as a minor fault, a serious fault, or an early fault, a late fault, etc., which is not limited in this disclosure.

[0079] In addition, in order to further avoid detecting component failures due to occasional abnormal vibrations, retesting can be performed when the Nth effective value is detected to be greater than the preset signal threshold. If the retest result is still that the Nth effective value is greater than the preset signal threshold, it is preliminarily determined that the component is abnormal and the state level of the target object is determined based on the N effective values. If the retest result is that the Nth effective value is less than or equal to the preset signal threshold, it is determined that the component is not abnormal and no subsequent judgment is required.

[0080] In a possible manner, the signal detection unit is further used to collect vibration waveform data of the target object and send it to the signal analysis terminal when the Nth effective value is greater than a preset signal threshold. The signal analysis terminal is also used to determine the fault location detection result of the target object according to the vibration waveform data.

[0081] For example, when the signal detection unit determines that the target object has abnormal vibration, the vibration waveform data of the target object can be collected and sent to the signal analysis terminal. The signal analysis terminal analyzes the vibration waveform data to determine the fault location of the target object. It can also combine the fault status detection results of the target object and the engine speed data of the equipment group where the target object is located to perform a comprehensive fault analysis and send the analysis results to the unit management and maintenance personnel.

[0082] In a possible manner, the signal analysis terminal is also used to send a detection instruction to the signal detection unit when the device group where the target object is located meets the preset detection start condition. The preset detection start condition includes that the generator speed of the device group reaches the rated speed during the first detection after the device group is started, or the generator speed of the device group reaches the rated speed during the non-first detection after the device group is started, and the time interval from the last detection time is greater than or equal to the preset time interval. The signal detection unit is also used to identify the electrical signal in response to the detection instruction to obtain N valid values ​​corresponding to N frequency bands. Among them, the preset time interval can be set according to demand, and the present disclosure does not limit this.

[0083] In addition, after a test is completed, the working state of the signal detection unit can be changed to a low-power sleep state to wait for the next test instruction, thereby reducing power consumption. If the signal analysis terminal determines that the unit is shut down based on the engine speed data, it stops sending the test instruction and waits for the unit to start. If the unit is not shut down, the next test will start after the preset test start conditions are met.

[0084] Based on the same inventive concept, the embodiment of the present disclosure further provides a device detection method, which is applied to a device detection system. The system includes a vibration sensing unit, a signal detection unit, and a signal analysis terminal. The method includes:

[0085] S301: A vibration sensing unit converts mechanical vibration of a target object into an electrical signal.

[0086] S302: The signal detection unit identifies the electrical signal to obtain N effective values ​​corresponding to N frequency bands.

[0087] Among them, the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1.

[0088] S303: When the Nth effective value corresponding to the Nth frequency band is greater than a preset signal threshold, the signal detection unit determines a state level of the target object based on the N effective values, and sends the state level to the signal analysis terminal.

[0089] S304: The signal analysis terminal determines a fault state detection result of the target object according to the state level.

[0090] By adopting the above method, the fault status detection results are obtained by analyzing the effective values ​​of multiple vibration frequency bands of the target object, which can reduce the probability of misjudgment caused by occasional abnormal vibrations, and the detection results can be obtained without manual analysis, thereby improving the accuracy and reliability of fault detection of the target object and reducing labor costs.

[0091] Optionally, the system further includes an energy conversion unit and an energy collection unit, and the method further includes:

[0092] The transducer unit converts the mechanical vibration of the target object into electrical energy;

[0093] The energy collection unit stores the electric energy and supplies power to the signal detection unit.

[0094] Optionally, the method further comprises:

[0095] When the Nth effective value is less than or equal to the preset signal threshold, the signal detection unit determines that the state level of the target object is a first level, and the first level indicates that no fault occurs to the target object.

[0096] Optionally, the N frequency bands are 4 frequency bands, and the N valid values ​​corresponding to the N frequency bands are respectively a first valid value corresponding to the first frequency band, a second valid value corresponding to the second frequency band, a third valid value corresponding to the third frequency band, and a fourth valid value corresponding to the fourth frequency band, and determining the state level of the target object based on the N valid values ​​includes:

[0097] The signal detection unit determines a first ratio of the first effective value to the fourth effective value, determines a second ratio of the second effective value to the fourth effective value, and determines a third ratio of the third effective value to the fourth effective value;

[0098] The signal detection unit determines that the state level of the target object is the second level when the third ratio is greater than the first ratio and the third ratio is greater than the second ratio;

[0099] The signal detection unit determines that the state level of the target object is a third level when the second ratio is greater than the first ratio and the second ratio is greater than the third ratio;

[0100] The signal detection unit determines that the state level of the target object is a fourth level when the first ratio is greater than the second ratio and the first ratio is greater than the third ratio;

[0101] The fault severity represented by the second level, the third level and the fourth level increases in sequence.

[0102] Optionally, the method further comprises:

[0103] The signal detection unit collects the vibration waveform data of the target object and sends it to the signal analysis terminal when the Nth effective value is greater than a preset signal threshold;

[0104] The signal analysis terminal determines a fault location detection result of the target object based on the vibration waveform data.

[0105] Optionally, the method further comprises:

[0106] The signal analysis terminal sends a detection instruction to the signal detection unit when the device group where the target object is located meets the preset detection start condition, and the preset detection start condition includes that the generator speed of the device group reaches the rated speed during the first detection after the device group is started, or the generator speed of the device group reaches the rated speed during the non-first detection after the device group is started, and the time interval from the last detection time is greater than or equal to the preset time interval;

[0107] The signal detection unit identifies the electrical signal in response to the detection instruction to obtain the N effective values ​​corresponding to the N frequency bands.

[0108] Regarding the device detection method in the above embodiment, the specific method of the operation performed by each module of the device detection system has been described in detail in the embodiment of the device detection system, and will not be elaborated here.

[0109] In order to enable those skilled in the art to better understand the method steps executed by each module in the device detection system provided by the present disclosure, a detailed embodiment description is given below in conjunction with the device detection system and the device detection method.

[0110] Reference Figure 4The vibration sensing transducer assembly includes a vibration sensing element (vibration sensing unit) and a transducer element (transducer unit), wherein the vibration sensing element is used to convert the mechanical vibration of the target object into an electrical signal, and the transducer element is used to convert the mechanical vibration of the target object into electrical energy. The vibration sensing transducer assembly is encapsulated in a cylindrical housing made of stainless steel, the base of the housing is hexagonal, and is designed with a threaded blind hole for fixed installation to meet the requirements of lightweight, miniaturization, and convenient installation. The signal detection assembly includes a signal detection unit and an energy collection unit, wherein the signal detection unit is used to realize the functions of vibration signal conditioning, collection, and signal reception and transmission, and the energy collection unit is used to realize the rectification processing of the electrical energy obtained from vibration conversion, the charging and discharging of the energy storage element, power management, and component power supply. Both are encapsulated in another cylindrical housing made of stainless steel, the base of the housing is hexagonal, and is designed with a threaded blind hole for fixed installation. The signal analysis terminal is an intelligent terminal device equipped with signal analysis software, which is used to realize vibration signal detection control, vibration data analysis and other functions. The power supply system is a 220V AC power supply, which can be powered by the wind turbine cabin control cabinet to power the signal analysis terminal.

[0111] Specifically, the signal detection unit includes a vibration signal conditioning circuit, a 1-to-4 signal follower, a vibration signal A\B\C\D frequency band filter (wherein, the A frequency band is a low frequency band, the B frequency band is a medium frequency band, the C frequency band is a high frequency band, the lower limit frequency of the D frequency band is the lower limit frequency of the A frequency band, and the upper limit frequency of the D frequency band is the upper limit frequency of the C frequency band), a multi-channel synchronous true effective value conversion circuit, a multi-channel synchronous AD sampling circuit, an analog measurement power management circuit, a microprocessor, a data storage device, a wireless transceiver circuit, etc., wherein the vibration signal conditioning circuit, the signal follower, the filter, the true effective value conversion circuit, and the AD sampling circuit constitute the analog measurement circuit of the signal detection unit. The energy collection unit includes a transducer circuit, a super capacitor, a charging circuit, a discharge circuit, a power management circuit, etc., and provides an external charging interface.

[0112] It should be noted that during the installation and deployment process, the measurement point location and the installation and deployment plan of each component of the equipment detection system are determined according to the structural form of the unit under test. And determine whether the signal detection component has sufficient power. If the power is insufficient, it can be charged using an external power supply through the external charging interface.

[0113] Furthermore, when the unit is shut down, a vibration sensing transducer assembly is installed at each selected measuring point, and a suitable position is selected near the measuring point to fix the signal detection assembly. If the selected measuring point has a reserved installation threaded hole, the assembly is fixed by a threaded connection installation method. If the selected measuring point does not have a reserved installation threaded hole, in order to avoid damaging the original structure of the measured component, it can be fixed by a magnetic suction seat installation method. Under this installation method, if the unit needs to be monitored for a long time, AB structural glue can be applied between the bottom surface of the magnetic suction seat and the adsorption surface of the measured component to ensure the secure installation of the assembly in the long-term monitoring application scenario. After the installation is completed, the two components are connected with a multi-core cable to realize the transmission of vibration signals and electrical energy. Finally, the signal analysis terminal is deployed near the cabin control cabinet, and the 220V AC power supply is taken from the cabin control cabinet to power the system. At the same time, the speed signal (generator speed) in the unit's own measurement system is connected to the signal analysis terminal.

[0114] It is worth noting that the specific circuits, devices, component materials, shapes, fixing methods, power supply sizes, etc. provided in the above embodiments are all exemplary descriptions, and they can be replaced in actual use as long as they can meet the corresponding use requirements. For example, the housing base can be round, etc., and the present disclosure does not limit this.

[0115] Reference Figure 5 After the unit is started, the signal analysis terminal continuously reads the unit speed (generator speed) data and determines whether the preset detection start-up conditions are met. If the preset detection start-up conditions are met, the signal analysis terminal sends a detection instruction to the signal detection component wirelessly. If the preset detection start-up conditions are not met, continue to wait until the conditions are met. Among them, the preset detection start-up conditions are: the first detection after the unit is started, the unit speed reaches the rated speed (allowable deviation ±5%), or the non-first detection after the unit is started, the unit speed reaches the rated speed (allowable deviation ±5%), and the time interval t from the last detection is greater than or equal to the preset time interval T.

[0116] Furthermore, after receiving the detection instruction sent by the signal analysis terminal, the signal detection component sends an enable signal to the analog measurement power management circuit in the signal detection unit to start supplying power to each component in the analog measurement circuit.

[0117] It should be noted that, according to the fault characteristic frequency of each measuring point component, and the corresponding relationship between the fault characteristic frequency and the degree of component fault development, the signal analysis terminal sends the center frequency and bandwidth parameters of the A, B, C, and D band filters to the microprocessor, and completes the filter setting through the microprocessor. For example, for the measuring point deployed at the bearing seat of the generator drive end, the A band filter of the signal detection component has a passband frequency range of 10Hz-300Hz, the B band filter has a passband frequency range of 300Hz-1000Hz, the C band filter has a passband frequency range of 1000Hz-5000Hz, and the D band filter has a passband frequency range of 10Hz-5000Hz.

[0118] During the detection process, the mechanical vibration of the tested component is converted into an analog electrical signal by the vibration sensing element in the vibration sensing transducer assembly and transmitted to the signal detection assembly. The signal detection assembly processes the vibration analog electrical signal to obtain the effective value of vibration in each frequency band (a RMS 、b RMS 、c RMS d RMS ). The effective value of the D-band vibration d RMS Compared with the preset signal threshold m, if d RMS If it is greater than m, a retest is performed. After the retest, d RMS If d is still greater than m, it is preliminarily determined that the vibration state of the tested component is abnormal. RMS If it is less than or equal to m, it is judged that the vibration state of the tested component is normal.

[0119] If the vibration state of the tested component is normal, the health status rating result (status level) is the first level. If the tested component is judged to be in an abnormal vibration state, it is necessary to further calculate and compare the ratio of the effective value of the vibration in the A, B, and C frequency bands to the effective value of the vibration in the D frequency band, and collect the vibration waveform data of the corresponding measuring point of the component through the AD sampling circuit. RMS Greater than m, and k c Greater than k a With k b When d RMS Greater than m, and k b Greater than k a With k c When d RMS Greater than m, and k a Greater than k b With k c When the state level of the target object is determined to be the fourth level, the health status rating results and vibration waveform data of each tested component are stored locally in the signal detection component. At the same time, the signal detection component sends the rating results and waveform data to the signal analysis terminal wirelessly.

[0120] The signal detection component then sends a shutdown signal to the analog measurement power management circuit in the signal detection unit, stopping the supply of power to the components in the analog measurement circuit. The signal detection component enters a low-power sleep state and waits for the next measurement. The signal analysis terminal analyzes the vibration waveform data, determines the location of the fault, and sends the unit component rating results, fault location and other detection conclusions to the unit management and maintenance personnel, and the single detection step is completed.

[0121] Finally, the signal analysis terminal continues to read the unit speed data. If the unit has been shut down, the current detection ends. If the unit has not been shut down, the next detection starts after the preset detection start conditions are met.

[0122] In summary, by using vibration detection technology, vibration transducer technology and micro energy storage technology, an equipment detection system integrating vibration detection, vibration transducer and micro energy storage system is designed, and a design scheme is adopted to separate the vibration sensing element and the vibration signal processing circuit. While improving the endurance of the detection device, it solves the problem of the narrow installation position of individual measuring points of the wind turbine transmission chain components. The signal analysis terminal and the signal detection component communicate wirelessly, without laying cables, reducing the difficulty and time of installation. By analyzing the failure mechanism and fault development law of the wind turbine transmission chain components, the fault status detection results are obtained by analyzing the effective values ​​of multiple vibration frequency bands of the object under test, and accurate early warning of the transmission chain components is achieved.

[0123] Of course, the above-mentioned equipment detection system and equipment detection method may be applied not only to wind turbines, but also to other equipment capable of performing fault detection by means of vibration detection, and the present disclosure does not limit this.

[0124] The preferred embodiments of the present disclosure are described in detail above in conjunction with the accompanying drawings; however, the present disclosure is not limited to the specific details in the above embodiments. Within the technical concept of the present disclosure, a variety of simple modifications can be made to the technical solution of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0125] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present disclosure will not further describe various possible combinations.

[0126] In addition, various embodiments of the present disclosure may be arbitrarily combined, and as long as they do not violate the concept of the present disclosure, they should also be regarded as the contents disclosed by the present disclosure.

Claims

1. A device detection system, characterized in that: The system includes a vibration sensing unit, a signal detection unit and a signal analysis terminal; The vibration sensing unit is used to convert the mechanical vibration of the target object into an electrical signal; The signal analysis terminal is used to send a detection instruction to the signal detection unit when the device group where the target object is located meets the preset detection start condition, and the preset detection start condition includes that the generator speed of the device group reaches the rated speed during the first detection after the device group is started, or the generator speed of the device group reaches the rated speed during the non-first detection after the device group is started, and the time interval from the last detection time is greater than or equal to the preset time interval; The signal detection unit is used to identify the electrical signal in response to the detection instruction, and obtain N effective values ​​corresponding to N frequency bands, wherein the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1; The signal detection unit is used to determine the state level of the target object based on the N valid values ​​when the N valid value corresponding to the N frequency band is greater than the preset signal threshold, and send the state level to the signal analysis terminal; The signal analysis terminal is used to determine the fault state detection result of the target object according to the state level; The N frequency bands are 4 frequency bands, the N valid values ​​corresponding to the N frequency bands are respectively a first valid value corresponding to the first frequency band, a second valid value corresponding to the second frequency band, a third valid value corresponding to the third frequency band, and a fourth valid value corresponding to the fourth frequency band, and the signal detection unit is used to: determining a first ratio of the first effective value to the fourth effective value, determining a second ratio of the second effective value to the fourth effective value, and determining a third ratio of the third effective value to the fourth effective value; When the third ratio is greater than the first ratio and the third ratio is greater than the second ratio, determining that the state level of the target object is the second level; When the second ratio is greater than the first ratio and the second ratio is greater than the third ratio, determining that the state level of the target object is the third level; When the first ratio is greater than the second ratio and the first ratio is greater than the third ratio, determining that the state level of the target object is a fourth level; The fault severity represented by the second level, the third level and the fourth level increases in sequence.

2. The system according to claim 1, characterized in that The system also includes an energy conversion unit and an energy collection unit; The energy conversion unit is used to convert the mechanical vibration of the target object into electrical energy; The energy collection unit is used to store the electric energy and supply power to the signal detection unit.

3. The system according to claim 1, characterized in that The signal detection unit is further configured to determine, when the Nth effective value is less than or equal to the preset signal threshold, that the state level of the target object is a first level, wherein the first level indicates that no fault occurs to the target object.

4. The system according to any one of claims 1 to 3, characterized in that: The signal detection unit is also used to collect the vibration waveform data of the target object and send it to the signal analysis terminal when the Nth effective value is greater than the preset signal threshold; The signal analysis terminal is also used to determine a fault location detection result of the target object based on the vibration waveform data.

5. The system according to claim 2, characterized in that The vibration sensing unit and the transducer unit are packaged in a first package component, the first package component is arranged at a preset detection point of the target object, the signal detection unit and the energy collection unit are packaged in a second package component, and the first package component and the second package component are connected by a cable; The signal analysis terminal communicates with the second packaging component wirelessly, and is connected to a control cabinet of the equipment group where the target object is located through a cable, so as to obtain power supply and generator speed data.

6. A device detection method, characterized in that: Applied to an equipment detection system, the system includes a vibration sensing unit, a signal detection unit and a signal analysis terminal, and the method includes: The vibration sensing unit converts the mechanical vibration of the target object into an electrical signal; The signal analysis terminal sends a detection instruction to the signal detection unit when the device group where the target object is located meets the preset detection start condition, and the preset detection start condition includes that the generator speed of the device group reaches the rated speed during the first detection after the device group is started, or the generator speed of the device group reaches the rated speed during the non-first detection after the device group is started, and the time interval from the last detection time is greater than or equal to the preset time interval; The signal detection unit identifies the electrical signal in response to the detection instruction, and obtains N effective values ​​corresponding to N frequency bands, wherein the lower limit frequency of the Nth frequency band is less than or equal to the lower limit frequency of the 1st frequency band, the upper limit frequency of the Nth frequency band is greater than or equal to the upper limit frequency of the N-1th frequency band, and the upper limit frequency of the i-th frequency band is equal to the lower limit frequency of the i+1th frequency band, N is a positive integer, and i is a positive integer less than N-1; The signal detection unit determines the state level of the target object based on the N valid values ​​when the N valid value corresponding to the N frequency band is greater than the preset signal threshold, and sends the state level to the signal analysis terminal; The signal analysis terminal determines a fault state detection result of the target object according to the state level; The N frequency bands are 4 frequency bands, and the N valid values ​​corresponding to the N frequency bands are respectively a first valid value corresponding to the first frequency band, a second valid value corresponding to the second frequency band, a third valid value corresponding to the third frequency band, and a fourth valid value corresponding to the fourth frequency band. Determining the state level of the target object based on the N valid values ​​includes: The signal detection unit determines a first ratio of the first effective value to the fourth effective value, determines a second ratio of the second effective value to the fourth effective value, and determines a third ratio of the third effective value to the fourth effective value; The signal detection unit determines that the state level of the target object is the second level when the third ratio is greater than the first ratio and the third ratio is greater than the second ratio; The signal detection unit determines that the state level of the target object is a third level when the second ratio is greater than the first ratio and the second ratio is greater than the third ratio; The signal detection unit determines that the state level of the target object is a fourth level when the first ratio is greater than the second ratio and the first ratio is greater than the third ratio; The fault severity represented by the second level, the third level and the fourth level increases in sequence.

7. The method according to claim 6, characterized in that The system further includes an energy conversion unit and an energy collection unit, and the method further includes: The transducer unit converts the mechanical vibration of the target object into electrical energy, The energy collection unit stores the electric energy and supplies power to the signal detection unit.

8. The method according to claim 6, characterized in that The method further comprises: When the Nth effective value is less than or equal to the preset signal threshold, the signal detection unit determines that the state level of the target object is a first level, and the first level indicates that no fault occurs to the target object.

9. The method according to any one of claims 6 to 8, characterized in that: The method further comprises: The signal detection unit collects the vibration waveform data of the target object and sends it to the signal analysis terminal when the Nth effective value is greater than a preset signal threshold; The signal analysis terminal determines a fault location detection result of the target object based on the vibration waveform data.

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