An in-service detection system and detection method for the main shaft of a wind turbine generator

Abstract

The present invention discloses an in-service detection system and a detection method for the main shaft of a wind turbine generator. The detection system includes a solar panel, a power transmission cable, a detection device, and a laptop computer. The solar panel supplies power to the detection device. The detection device includes an outermost ring-shaped support, a cross-shaped rotating bracket, and a detection module. All components of the detection module are installed on the rotating bracket, and the rotating bracket drives the detection module to complete the circumferential scanning of the end of the main shaft of the wind turbine. The detection device collects detection data through a scanning device, and after data processing, it is wirelessly transmitted to the operation terminal of the laptop computer to complete the in-service detection work of the main shaft. The present invention adopts a modular design, and the operation state of the wind turbine has no influence on the detection, which improves the detection reliability and repeatability, has a fast detection speed and high precision; has a reasonable structure, is convenient for disassembly and assembly of modules, is easy to maintain, and has a low cost; is applicable to the in-service detection of the main shafts of wind turbines with different model specifications and diameters, and has strong versatility.

Description

Technical Field

[0001] The present invention relates to an in-service detection system and a detection method for a main shaft of a wind turbine generator, belonging to the field of industrial detection equipment manufacturing. Background Art

[0002] In recent years, the installed capacity of wind power in China has been continuously increasing, and the contribution of wind power to the national power supply has been continuously improving. According to relevant statistics, in 2021, the wind power in the whole country showed a high-quality leapfrog development trend. The grid-connected installed capacity of wind power exceeded 300 million kilowatts, the wind power generation exceeded 600 billion kWh, the newly installed capacity of offshore wind power increased significantly, and the utilization rate of wind power gradually increased. With the large-scale production and operation of wind turbine generators, the quality of the main components in the wind turbines and the operating conditions of the units have attracted more and more attention.

[0003] As one of the three important components of wind power generation equipment, the main shaft of the wind turbine is an important component connecting the wind turbine blades and the nacelle. Its technical parameters, mechanical properties have high requirements, and the geometric tolerance and dimensional tolerance are strictly required. At the same time, the main shaft belongs to a rotating component, which is subjected to fatigue, bending, torsion, and even tensile stress for a long time, and is prone to fatigue defects and crack initiation sources, ultimately leading to the occurrence of main shaft fracture accidents. Once the main shaft fractures, it will cause the blades and the hub to fall from a height, causing major damage to the unit and even scrapping the whole machine. Therefore, the demand for main shaft detection of wind turbines has increased sharply, and at the same time, higher requirements have been put forward for non-destructive testing technology.

[0004] At present, manual ultrasonic testing technology is usually used for non-destructive testing of the main shaft of wind turbines: before testing, grid lines or concentric circles are drawn in advance at the end of the forging. After brushing or spraying the coupling agent, the ultrasonic probe is held by hand and the ultrasonic scanning is carried out along the line. The following problems generally exist in conventional ultrasonic testing: the height of wind turbines is generally more than 60 meters, and the wind turbines often have different degrees of shaking. During testing, the staff needs to crawl through the manhole of the nacelle to reach the hub bin area and conduct testing at the end of the main shaft. This requires high requirements for the testing personnel and has a high safety risk; because the personnel are working at a high altitude in the hub bin area, it is necessary to stop the machine for testing and it is impossible to achieve in-service testing; the main shaft detection belongs to a high-altitude operation project with relatively high risks. The personnel need to hold a professional high-altitude operation certificate and a testing certificate, and the performance requirements for the instrument and equipment are high. Therefore, the testing cost is high; the manual testing speed is slow and the efficiency is low. Usually, only one main shaft of a wind turbine can be detected in a day; the maintenance cycle of the wind turbine is long. Usually, the main shaft of the wind turbine is detected once every two years. Therefore, new defects cannot be detected in time, and existing defects cannot be monitored in time; holding the probe by hand cannot ensure uniform probe pressure, resulting in a large change in the detection sensitivity during the scanning process, poor repeatability of the detection results, and low detection accuracy. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an in-service detection system and detection method for the main shaft of a wind turbine generator in view of the defects existing in the prior art, so as to realize the automated phased array ultrasonic detection of remote control of the main shaft of the wind turbine, solve various problems existing in manual ultrasonic detection, and improve the detection quality and efficiency.

[0006] To solve this technical problem, the present invention provides an in-service detection system for the main shaft of a wind turbine generator, which includes a solar panel, a power transmission cable, a detection device and a laptop computer. The solar panel generates electric energy, and the electric energy is transmitted through the power transmission cable to the battery module of the detection device for storage to supply power to the detection device. The detection device is in an overall disc shape and includes an outermost annular support, a cross-shaped rotating bracket and a detection module. Four rubber wheels are arranged at the ends of the rotating bracket, and the rubber wheels are clamped into the annular track grooves inside the support, so that the rotating bracket is installed together with the support. All components of the detection module are installed on the rotating bracket, and the rotating bracket can freely rotate inside the support to drive the detection module to complete the circumferential scanning of the end of the main shaft of the wind turbine. The detection device is installed at the end of the main shaft of the wind turbine. Detection data is collected through its scanning device, and after data processing, it is wirelessly transmitted to the operation terminal of the laptop computer, and the in-service detection work of the main shaft is completed through remote control of the laptop computer.

[0007] The support includes an annular track and three legs. The annular track is a hollow structure, and the inner ring side is provided with a track matching the specification of the rubber wheel. The three legs are equidistantly distributed around the annular track and are fixed to the outside of the annular track by welding.

[0008] The leg includes a magnetic switch, a magnetic base, a knurled flat head screw I, a circular ring support arm and a column support rod I. A disc-shaped magnetic base is provided at the lower part of the column support rod I, and a knob-type magnetic switch is arranged on the side of the magnetic base. The application and release of the magnetic force in the magnetic base can be controlled by rotating the magnetic switch. The upper end of the column support rod I passes through the circular ring support arm fixed on the annular track to complete the assembly of the leg. A knurled flat head screw I is arranged on the side of the circular ring support arm. The height of the detection device can be adjusted by adjusting the length of the column support rod I leaking out, and after the device height is determined, the knurled flat head screw I is tightened to fix the column support rod I.

[0009] The rotating bracket includes a cross body, a servo motor, a rubber wheel and a straight tooth rack. Its main structure is a cross body. A servo motor is installed at the end of each of the four arms of the cross body, and a rubber wheel is installed at the front end of each of the four servo motors. The outer side of the rubber wheel is processed into an inclined surface, and its specification size matches the inner track of the annular track. The rubber wheel can freely rotate inside the annular track. The servo motor drives the rubber wheel to rotate, so as to realize the circumferential movement of the rotating bracket. A groove is provided on the upper surface of one of the arms of the cross body, and a straight tooth rack is installed inside the groove for cooperation with the scanning device.

[0010] The detection module includes five sub-modules: a phased array ultrasonic processor, a controller, a battery, an oil pump, and a scanning device. Each of the above modules is fixedly installed on a rotating bracket. The four sub-modules of the phased array ultrasonic processor, the controller, the battery, and the oil pump are arranged in a line on the rotating bracket and are connected together through control cables and are uniformly controlled by the controller. The battery powers the detection device. The phased array ultrasonic processor is responsible for collecting and processing detection data. The oil pump pumps oil to the phased array probe through an oil delivery pipe as a coupling agent for the phased array probe. Three indicator lights are arranged on the surface of the phased array ultrasonic processor for displaying the processor status. A button switch is arranged on the surface of the controller for controlling the start and stop of the system. A liquid crystal display screen is arranged on the surface of the battery for displaying the battery power.

[0011] The scanning device includes a phased array probe, a driving motor, and a second column support rod. The driving motor provides power for the scanning device. A spur gear is installed at the front end of the central axis of the driving motor. The spur gear meshes with the spur rack on the cross-shaped body. The driving motor drives the spur gear to roll back and forth on the spur rack, thereby realizing the forward and backward movement of the scanning device. The phased array probe is fixed at the lower end of the second column support rod. The upper end of the second column support rod passes through the positioning hole of the driving motor housing to connect the phased array probe with the driving motor. The phased array probe is connected to the phased array ultrasonic processor through a probe cable. The phased array ultrasonic processor controls the phased array probe to collect detection data and processes the detection data. Finally, the detection data is transmitted to the notebook computer operation terminal for display through the controller.

[0012] The second column support rod is divided into two sections. The diameter of the lower section is smaller and is inserted into the upper support rod. A spring is arranged between the two sections of the support rod, which can provide a pressing force for the phased array probe to ensure good contact between the phased array probe and the end face of the main shaft of the wind turbine. By adjusting the extended length of the second column support rod, the position of the phased array probe can be adjusted to adapt to the detection of main shafts of different specifications.

[0013] Two rubber oil pipe limit blocks are arranged on the second column support rod. The oil pipe limit blocks can move on the second column support rod and are used to fix the oil delivery pipe so that the oil can be accurately placed near the phased array probe as a coupling agent for the detection of the phased array probe.

[0014] The present invention also provides an assembly method for the in-service detection system of the main shaft of the wind turbine generator set as described above, and the steps are as follows:

[0015] 1) According to the outer dimension of the solar panel, installation holes are processed on the surface of the hub of the wind turbine generator set, the solar panel is installed and fixed, and a light-transmitting protective cover is additionally installed on the surface.

[0016] 2) Assemble the components of the detection device, place the detection device on the end face of the main shaft of the fan, ensure that the center of the detection device is on the center line of the main shaft of the fan, and toggle the magnetic switch one by one to make the magnetic base magnetic, and fix the detection device at the end of the main shaft of the fan;

[0017] 3) Adjust the position of the annular track so that the end face of the rotating bracket is parallel to the end face of the main shaft of the fan, and tighten the knurled flat head screws one by one to fix the first column support rod in the circular ring support arm;

[0018] 4) Push and pull the second column support rod to adjust the position of the phased array probe so that the phased array probe is in good contact with the end face of the main shaft of the fan and the applied pressure is appropriate;

[0019] 5) Tighten the second knurled flat head screw 3 to fix the second column support rod;

[0020] 6) Insert one end of the power transmission cable into the connection port of the solar panel and the other end into the battery interface. The detection system is powered on, and press the switch button on the surface of the controller to start the detection system.

[0021] The present invention also provides a method for in-service detection of the main shaft of a wind turbine generator set by using the detection system, and the detection steps are as follows:

[0022] 1) Turn on the laptop computer and connect to the detection device wirelessly;

[0023] 2) The four servo motors located at the end of the rotating bracket are started synchronously, and the rotating bracket drives the scanning device to move along the circumference. At the same time, the oil pump pumps oil to the position of the phased array probe through the oil transmission pipe;

[0024] 3) The phased array probe rotates synchronously and performs phased array ultrasonic detection on the main shaft of the fan;

[0025] 4) Data is synchronously collected, transmitted to the phased array ultrasonic processor through the probe cable, and finally real-time data transmission is carried out between the controller and the operation terminal of the laptop computer;

[0026] 5) The laptop computer processes and stores the detection data and displays the detection results;

[0027] 6) After the detection is completed, the operation terminal of the laptop computer issues a sleep command to the detection system. When detection is required, connect to the detection device again to repeat the detection work.

[0028] Advantages: The present invention is powered by a solar panel and is equipped with a battery module for storing electricity, forming a self-sufficient independent system. There is no need to lay power lines inside the wind turbine hub, and it can be installed synchronously during the construction of the wind power generation unit, making it convenient for installation and use. It has a wireless transmission function, allowing inspectors to remotely control it on a laptop computer without the need to climb to the high-altitude wind turbine hub for operation, eliminating safety risks and making inspection and use convenient. It adopts a modular design concept with a reasonable structural layout, easy disassembly and assembly of modules, simple maintenance, and low usage costs. The mechanical automatic scanning device can achieve uniform movement of the probe and automatic supply of the coupling agent, reducing the interference of human factors, improving the detection reliability and repeatability, with fast detection speed and high accuracy. The solar panel is installed on the outer surface of the wind turbine hub, and the detection device is installed at the end of the main shaft, both rotating synchronously with the hub, with a stationary relative position. After installation, in-service inspection can be achieved, and the operation state of the wind turbine has no impact on the detection. Through remote control, the main shaft of the wind turbine can be inspected at any time, facilitating the timely discovery of defects and also enabling the operation monitoring of existing defects. This detection system has an automatic data analysis function, automatically analyzing and comparing the previous detection data of the main shaft. The defect determination is intuitive and accurate both qualitatively and quantitatively. The present invention is applicable to the in-service inspection of the main shafts of wind turbines with different models and different specifications of diameters. It only needs to adjust the height of the support and the position of the probe according to the size of the main shaft to implement the detection, with good process applicability, strong versatility, and high economic benefits. Brief Description of the Drawings

[0029] Figure 1 is the overall structural schematic diagram of the present invention;

[0030] Figure 2 is the structural schematic diagram of the detection device of the present invention;

[0031] Figure 3 is the structural decomposition schematic diagram of the detection device of the present invention;

[0032] Figure 4 is the structural schematic diagram of the support of the present invention;

[0033] Figure 5 is the structural schematic diagram of the leg of the present invention;

[0034] Figure 6 is the structural schematic diagram of the rotating bracket of the present invention;

[0035] Figure 7 is the combined schematic diagram of the rotating bracket and the support of the present invention;

[0036] Figure 8 is the structural schematic diagram of the detection module of the present invention;

[0037] Figure 9 is the structural schematic diagram of the scanning device of the present invention;

[0038] Figure 10 This is a schematic diagram of the on-site application of the detection system of the present invention.

[0039] In the figure: 1. Solar panel; 2. Power transmission cable; 3. Detection device; 4. Laptop; 5. Wind turbine main shaft; 31. Support; 32. Rotating bracket; 33. Detection module; 311. Ring track; 312. Leg; 3121. Magnetic switch; 3122. Magnetic base; 3123. Knurled flat head screw 1; 3124. Ring arm; 3125. Column support rod 1; 321. Cross body; 322. Servo motor; 323. Rubber wheel; 324. Straight tooth rack; 331. Phased array ultrasonic processor; 332. Control cable; 333. Controller; 334. Battery; 335. Oil pump; 336. Oil pipeline; 337. Scanning device; 3371. Phased array probe; 3372. Probe wire; 3373. Driving motor; 3374. Straight tooth gear; 3376. Knurled flat head screw 2; 3377. Oil pipeline limit block; 3378. Column support rod 2. Specific embodiments

[0040] The following describes the present invention in detail with reference to the accompanying drawings and embodiments.

[0041] As Figures 1-10 shown, the present invention provides an in-service detection system for the main shaft of a wind turbine generator, including a solar panel 1, a power transmission cable 2, a detection device 3 and a laptop 4. The solar panel 1 generates electric energy, and the electric energy is transmitted through the power transmission cable 2 to the battery module of the detection device 3 for storage, and powers the detection device 3. The detection device 3 is integrally disc-shaped, including the outermost ring support 31, a cross-shaped rotating bracket 32 and a detection module 33. Four rubber wheels 323 are arranged at the end of the rotating bracket 32, and the rubber wheels 323 are clamped into the groove of the ring track 311 inside the support 31, so that the rotating bracket 32 is installed with the support 31. All components of the detection module 33 are installed on the rotating bracket 32. The rotating bracket 32 can rotate freely inside the support 31, driving the detection module 33 to complete the circumferential scanning of the end of the wind turbine main shaft. The detection device 3 is installed at the end of the wind turbine main shaft 5, and the detection data is collected through its scanning device. After data processing, it is wirelessly transmitted to the operation terminal of the laptop 4, and the in-service detection of the main shaft is completed through remote control of the laptop 4.

[0042] The support 31 includes a ring track 311 and three legs 312. The ring track 311 is a hollow structure, and the inner ring side is provided with a track matching the specification of the rubber wheel 323. The three legs 312 are equidistantly distributed around the ring track 311 and are fixed to the outside of the ring track 311 by welding, forming an equilateral triangle arrangement to provide stable support for the support 31.

[0043] The outrigger 312 includes a magnetic switch 3121, a magnetic base 3122, a knurled flat head screw 3123, a ring-shaped support arm 3124, and a first column support rod 3125. A disc-shaped magnetic base 3122 is provided at the lower part of the first column support rod 3125. A knob-type magnetic switch 3121 is arranged on the side of the magnetic base 3122. By rotating the magnetic switch 3121, the application and release of the magnetic force in the magnetic base 3122 can be controlled to achieve the purpose of installing and fixing the detection device 3. The upper end of the first column support rod 3125 passes through the ring-shaped support arm 3124 fixed on the annular track 311 to complete the assembly of the outrigger 312. A knurled flat head screw 3123 is provided on the side of the ring-shaped support arm 3124. The height of the detection device can be adjusted by adjusting the length of the first column support rod 3125 protruding out. After the device height is determined, the knurled flat head screw 3123 is tightened to fix the first column support rod 3125.

[0044] The rotating bracket 32 includes a cross-shaped body 321, a servo motor 322, a rubber wheel 323, and a straight tooth rack 324. Its main structure is a cross-shaped body 321. A servo motor 322 is installed at the end of each of the four support arms of the cross-shaped body 321. A rubber wheel 323 is installed at the front end of each of the four servo motors 322. The outer side of the rubber wheel 323 is processed into an inclined surface, and its specification dimensions match the inner track of the annular track 311. The rubber wheel 323 can rotate freely inside the annular track 311. The servo motor 322 drives the rubber wheel 323 to rotate, thereby realizing the circumferential movement of the rotating bracket 32. A groove is provided on the upper surface of one of the support arms of the cross-shaped body 321, and a straight tooth rack 324 is installed inside the groove for cooperation with the scanning device. The rack specification matches the straight tooth gear in the scanning device and provides a moving track for the scanning device.

[0045] The detection module 33 includes five sub-modules: a phased array ultrasonic processor 331, a controller 333, a battery 334, an oil pump 335, and a scanning device 337. The above-mentioned sub-modules are all fixedly installed on the rotating bracket 32. The four sub-modules of the phased array ultrasonic processor 331, the controller 333, the battery 334, and the oil pump 335 are arranged in a row on the rotating bracket 32 and are connected together by a control cable 332 and are uniformly controlled by the controller 333. The battery 334 supplies power to the detection device 3. The phased array ultrasonic processor 331 is responsible for collecting and processing detection data. The oil pump 335 pumps oil to the phased array probe part through an oil pipeline 336 as a coupling agent for the phased array probe. Three indicator lights are arranged on the surface of the phased array ultrasonic processor 331 for displaying the status of the processor. A button switch is arranged on the surface of the controller 333 for controlling the start and stop of the system. A liquid crystal display screen is arranged on the surface of the battery 334 for displaying the battery power.

[0046] The scanning device 337 includes a phased array probe 3371, a driving motor 3373, and a second column support rod 3378. The driving motor 3373 provides power for the scanning device 337. A spur gear 3374 is installed at the front end of the central axis of the driving motor 3373. The spur gear 3374 meshes with the spur rack 324 on the cross-shaped body 321. The driving motor 3373 drives the spur gear 3374 to roll back and forth on the spur rack 324, thereby realizing the forward and backward movement of the scanning device 337. The phased array probe 3371 is fixed at the lower end of the second column support rod 3378. The upper end of the second column support rod 3378 passes through the positioning hole of the housing of the driving motor 3373, connecting the phased array probe 3371 with the driving motor 3373. The phased array probe 3371 is connected to the phased array ultrasonic processor 331 through a probe cable 3372. The phased array ultrasonic processor 331 controls the phased array probe 3371 to collect detection data and processes the detection data. Finally, the detection data is transmitted to the operation terminal of the laptop computer 4 through the controller 333 for display.

[0047] The second column support rod 3378 is divided into two sections. The lower section has a smaller diameter and is inserted into the upper support rod. A spring is arranged between the two sections of the support rod, which can provide a pressing force on the phased array probe 3371 to ensure good contact between the phased array probe 3371 and the end face of the fan main shaft. By adjusting the extended length of the second column support rod 3378, the position of the phased array probe 3371 can be adjusted to suit the detection of main shafts of different specifications.

[0048] Two rubber oil pipe limit blocks 3377 are arranged on the second column support rod 3378. The oil pipe limit blocks 3377 can move on the second column support rod 3378 and are used to fix the oil delivery pipe 336, so that the engine oil can be accurately placed near the phased array probe 3371 as a coupling agent for the detection of the phased array probe 3371.

[0049] The assembly steps of the in-service detection system for the main shaft of the wind turbine generator are as follows:

[0050] 1) According to the outer dimension of the solar panel 1, installation holes are machined on the surface of the wind turbine generator hub, and the solar panel 1 is installed and fixed, and a light-transmitting protective cover is added to the surface.

[0051] 2) Assemble the components of the detection device 3. Place the detection device 3 on the end face of the fan main shaft 5, ensure that the center of the detection device 3 is on the center line of the fan main shaft 5, and toggle the magnetic switch 3121 one by one to make the magnetic base 3122 magnetic, and fix the detection device 3 at the end of the fan main shaft 5.

[0052] 3) Adjust the position of the annular track 311 so that the end face of the rotating bracket 32 is parallel to the end face of the main shaft 5 of the fan. Tighten the knurled flat head screws 3123 one by one to fix the column support rod 3125 in the circular ring support arm 3124;

[0053] 4) Push and pull the column support rod 3378 of the second column to adjust the position of the phased array probe 3371 so that the phased array probe 3371 is in good contact with the end face of the main shaft 5 of the fan, and apply appropriate pressure;

[0054] 5) Tighten the knurled flat head screws 3376 of the second column to fix the column support rod 3378 of the second column;

[0055] 6) Insert one end of the power transmission cable 2 into the connection port of the solar panel 1 and the other end into the interface of the battery 334. Check whether the system is charged. Press the switch button on the surface of the controller 333 to start the detection system.

[0056] When using the in-service detection system for the main shaft of the wind turbine generator set to conduct detection and flaw detection, the detection method steps are as follows:

[0057] 1) Turn on the laptop 4, connect to the detection device 3 through wireless connection. After the connection is successful, the detector operates the laptop 4 to remotely control the detection device 3 to conduct detection;

[0058] 2) The four servo motors located at the end of the rotating bracket 32 are started synchronously. The rotating bracket 32 drives the scanning device 337 to move along the circumference. At the same time, the oil pump 335 pumps oil to the position of the phased array probe 3371 through the oil transmission pipe 336;

[0059] 3) The phased array probe 3371 rotates synchronously and conducts phased array ultrasonic detection on the main shaft 5 of the fan;

[0060] 4) Data is synchronously collected, transmitted to the phased array ultrasonic processor 331 through the probe cable 3372, and finally real-time data transmission is carried out between the controller 333 and the operation end of the laptop 4;

[0061] 5) The laptop 4 processes and stores the detection data and displays the detection results;

[0062] 6) After the detection is completed, the operation end of the laptop 4 issues a sleep command for the detection system. When detection is required, connect to the detection device 3 again to repeat the detection work.

[0063] The present invention has the following characteristics:

[0064] 1. The present invention is powered by a solar panel. The detection device is installed at the end of the main shaft of the fan and is remotely controlled by a laptop to complete the in-service detection work of the main shaft. It is a self-sufficient independent system, without the need to lay power lines inside the fan hub, and can be installed synchronously during the construction of the wind turbine generator set, which is convenient for installation and use;

[0065] 2. The whole of the present invention is in a disc shape and is suitable for detecting the circular end faces of shaft forgings. The detection module is fixedly installed on the rotating bracket, and the rotating bracket is connected to the annular track through rubber wheels. The rotating bracket can rotate freely inside the support, driving the detection module to complete the circumferential scanning of the end of the fan main shaft, and the operation state of the fan has no influence on the detection implementation;

[0066] 3. The legs of the present invention are welded to the annular track at equal intervals and have a triangular stable structure. Cooperating with the switch-type magnetic base, the detection device can be fixed quickly and reliably, and can also be removed quickly;

[0067] 4. The present invention is assembled through the structurally matched rubber wheels and track grooves, assembling the rotating bracket and the circular support together. At the same time, the movement of the rotating bracket is controlled by a servo motor to accurately realize the circumferential scanning of the phased array probe. The structural connection is convenient, the installation is firm, and the rotation is stable;

[0068] 5. The present invention adopts a combined structure of a spur rack and a spur gear, and can conveniently and quickly realize the forward and backward movement of the scanning device under the action of the driving motor, and can quickly realize the precise positioning of the phased array probe. The structure is simple and easy to use;

[0069] 6. The column support rod and the knurled flat head screw of the present invention are used in combination, with a simple structure and convenient adjustment, and can quickly adjust the height of the support and the position of the probe;

[0070] 7. The present invention has a coupling agent pumping structure. The oil pump and the scanning device are both fixed on the rotating bracket, and the oil used as the coupling agent is pumped to the position of the phased array probe through an oil pipeline, which is convenient for the positioning and arrangement of the oil pipeline.

[0071] 8. The detection module of the present invention is composed of different functional sub-modules, which are connected by control cables to each other. The disassembly and assembly are convenient, and only the problem module needs to be replaced during maintenance, which is convenient for maintenance.

[0072] The present invention is powered by a solar panel, and a battery module is provided to store electricity. There is no need to lay power lines inside the wind turbine hub, and it can be installed synchronously during the construction of the wind turbine generator set, which is convenient to use. It has a wireless transmission function. The detection personnel only need to remotely control it on the laptop computer side, without having to climb to the high-altitude wind turbine hub for operation, so there is no safety risk and it is convenient to detect and use. It adopts a modular design concept, with a reasonable structure layout, convenient disassembly and assembly of modules, simple maintenance and low use cost. The mechanical automatic scanning device can realize the uniform movement of the probe and the automatic supply of the coupling agent, reducing the interference of human factors, improving the detection reliability and repeatability, with a fast detection speed and high precision. The solar panel is installed on the outer surface of the wind turbine hub, and the detection device is installed at the end of the main shaft, both of which rotate synchronously with the hub, and their relative positions are stationary. After installation, in-service detection can be realized, and the operation state of the wind turbine has no influence on the detection implementation. Through remote control, the main shaft of the wind turbine can be detected at any time, which is convenient for timely discovery of defects and can also monitor the operation of existing defects. This detection system has an automatic data analysis function, automatically analyzes and compares the previous detection data of the main shaft, and the defect determination is intuitive and the qualitative and quantitative accuracy is high. The present invention is applicable to the in-service detection of the main shafts of wind turbines of different models and different specifications of diameters. Only by adjusting the height of the support and the position of the probe according to the size of the main shaft can the detection be implemented, with good process applicability and strong versatility.

[0073] The above embodiments of the present invention are only examples, not the only ones. All changes within the scope of the present invention or equivalent to the scope of the present invention are encompassed by the present invention.

Claims

1. An in-service detection system for the main shaft of a wind turbine generator, characterized in that: It includes a solar panel (1), a power transmission cable (2), a detection device (3) and a laptop computer (4). The solar panel (1) generates electrical energy, and the electrical energy is transmitted through the power transmission cable (2) to the battery module of the detection device (3) for storage to supply power to the detection device (3). The detection device (3) is in an overall disc shape and includes an outermost annular support (31), a cross-shaped rotating bracket (32) and a detection module (33). Four rubber wheels (323) are arranged at the ends of the rotating bracket (32). The rubber wheels (323) are clamped into the grooves of the annular track (311) inside the support (31), so that the rotating bracket (32) is installed together with the support (31). All components of the detection module (33) are installed on the rotating bracket (32). The rotating bracket (32) can rotate freely inside the support (31) to drive the detection module (33) to complete the circumferential scanning of the end of the fan main shaft. The detection device (3) is installed at the end of the fan main shaft (5). Detection data is collected through the scanning device (337) of the detection module (33). After data processing, it is wirelessly transmitted to the operation end of the laptop computer (4), and the in-service detection of the main shaft is completed through remote control of the laptop computer (4). The support (31) includes an annular track (311) and three legs (312). The annular track (311) is a hollow structure, and the inner ring side is provided with a track matching the specification of the rubber wheel (323). The three legs (312) are equidistantly distributed around the annular track (311) and are fixed to the outside of the annular track (311) by welding. The rotating bracket (32) includes a cross-shaped body (321), a servo motor (322), a rubber wheel (323) and a straight tooth rack (324). Its main structure is a cross-shaped body (321). A servo motor (322) is installed at the end of each of the four arms of the cross-shaped body (321), and a rubber wheel (323) is installed at the front end of each of the four servo motors (322). The outer side of the rubber wheel (323) is processed into an inclined surface, and its specification and size match the inner track of the annular track (311). The rubber wheel (323) can rotate freely inside the annular track (311). The servo motor (322) drives the rubber wheel (323) to rotate, so as to realize the circumferential movement of the rotating bracket (32). A groove is provided on the upper surface of one of the arms of the cross-shaped body (321), and a straight tooth rack (324) is installed inside the groove for cooperation with the scanning device (337). The detection module (33) includes five sub-modules: a phased array ultrasonic processor (331), a controller (333), a battery (334), an oil pump (335), and a scanning device (337). The five sub-modules are all fixedly installed on the rotating bracket (32). The four sub-modules of the phased array ultrasonic processor (331), the controller (333), the battery (334), and the oil pump (335) are arranged in a line on the rotating bracket (32) and are connected together by a control cable (332) and are uniformly controlled by the controller (333). The battery (334) powers the detection device (3). The phased array ultrasonic processor (331) is responsible for collecting and processing detection data. The oil pump (335) pumps oil to the phased array probe (3371) through an oil pipeline (336) as a couplant for the phased array probe. Three indicator lights are provided on the surface of the phased array ultrasonic processor (331) for displaying the processor status. A push-button switch is provided on the surface of the controller (333) for controlling the start and stop of the system. A liquid crystal display screen is provided on the surface of the battery (334) for displaying the battery power. The scanning device (337) includes a phased array probe (3371), a drive motor (3373), and a second column support rod (3378). The scanning device (337) is powered by the drive motor (3373). A spur gear (3374) is installed at the front end of the central axis of the drive motor (3373). The spur gear (3374) meshes with the spur rack (324) on the cross-shaped body (321). The drive motor (3373) drives the spur gear (3374) to roll back and forth on the spur rack (324), thereby realizing the forward and backward movement of the scanning device (337). The phased array probe (3371) is fixed at the lower end of the second column support rod (3378). The upper end of the second column support rod (3378) passes through the positioning hole of the drive motor (3373) housing to connect the phased array probe (3371) with the drive motor (3373). The phased array probe (3371) is connected to the phased array ultrasonic processor (331) through a probe cable (3372). The phased array ultrasonic processor (331) controls the phased array probe (3371) to collect detection data, processes the detection data, and finally transmits the detection data to the operation end of the laptop computer (4) for display through the controller (333).

2. The in-service detection system for the main shaft of a wind turbine generator set according to claim 1, wherein: The outrigger (312) includes a magnetic switch (3121), a magnetic base (3122), a knurled flat head screw I (3123), a ring-shaped support arm (3124) and a column support rod I (3125). A disc-shaped magnetic base (3122) is provided at the lower part of the column support rod I (3125). A knob-type magnetic switch (3121) is arranged on the side of the magnetic base (3122). By rotating the magnetic switch (3121), the application and release of the magnetic force in the magnetic base (3122) can be controlled. The upper end of the column support rod I (3125) passes through the ring-shaped support arm (3124) fixed on the annular track (311) to complete the assembly of the outrigger (312). A knurled flat head screw I (3123) is provided on the side of the ring-shaped support arm (3124). By adjusting the exposed length of the column support rod I (3125), the height of the detection device (3) can be adjusted. After the device height is determined, the knurled flat head screw I (3123) is tightened to fix the column support rod I (3125).

3. The in-service detection system for the main shaft of a wind turbine generator according to claim 2, characterized in that: The column support rod II (3378) is divided into two sections. The diameter of the lower section is smaller and it is inserted into the upper support rod. A spring is arranged between the two sections of the support rod, which can provide a pressing force for the phased array probe (3371) to ensure good contact between the phased array probe (3371) and the end face of the fan main shaft. By adjusting the extended length of the column support rod II (3378), the position of the phased array probe (3371) can be adjusted to suit the detection of main shafts of different specifications.

4. The in-service detection system for the main shaft of a wind turbine generator according to claim 2, wherein: Two rubber oil pipe limit blocks (3377) are arranged on the column support rod II (3378). The oil pipe limit blocks (3377) can move on the column support rod II (3378) and are used to fix the oil delivery pipe (336) so that the engine oil can be accurately placed near the phased array probe (3371) as a coupling agent for the detection of the phased array probe (3371).

5. An assembling method of an in-service detection system for a main shaft of a wind turbine generator set according to any one of claims 2-4, characterized in that: The assembly steps are as follows: 1) According to the outer dimension of the solar panel (1), installation holes are machined on the surface of the wind turbine hub, and the solar panel (1) is installed and fixed, and a light-transmitting protective cover is added to the surface. 2) Assemble the components of the detection device (3), place the detection device (3) on the end face of the fan main shaft (5), ensure that the center of the detection device (3) is on the center line of the fan main shaft (5), and turn the magnetic switch (3121) one by one to make the magnetic base (3122) magnetic, and fix the detection device (3) at the end of the fan main shaft (5). 3) Adjust the position of the annular track (311) to make the end face of the rotating bracket (32) parallel to the end face of the fan main shaft (5), and tighten the knurled flat head screw I (3123) one by one to fix the column support rod I (3125) in the ring-shaped support arm (3124). 4) Push and pull the column support rod II (3378) to adjust the position of the phased array probe (3371) to make the phased array probe (3371) in good contact with the end face of the fan main shaft (5) and apply an appropriate pressure. 5) Tighten the knurled flat head screw II (3376) to fix the column support rod II (3378). 6) Insert one end of the power transmission cable (2) into the connection port of the solar panel (1), and the other end into the interface of the battery (334). Check if the system is powered on. Press the switch button on the surface of the controller (333) to start the detection system.

6. A detection method for an in-service detection system of a main shaft of a wind turbine generator, characterized in that: Use the detection system according to any one of claims 1-4 to conduct in-service detection on the main shaft of the wind turbine generator. The method steps are as follows: 1) Turn on the laptop computer (4) and connect to the detection device (3) wirelessly. 2) The four servo motors (322) at the end of the rotating bracket (32) start synchronously. The rotating bracket (32) drives the scanning device (337) to move in a circular motion. At the same time, the oil pump (335) pumps oil through the oil pipeline (336) to the position of the phased array probe (3371). 3) The phased array probe (3371) rotates synchronously and conducts phased array ultrasonic detection on the main shaft (5) of the wind turbine. 4) Data is collected synchronously, transmitted through the probe cable (3372) to the phased array ultrasonic processor (331), and finally real-time data transmission is carried out between the controller (333) and the operation terminal of the laptop computer (4). 5) The laptop computer (4) processes and stores the detection data and displays the detection results. 6) After the detection is completed, the operation terminal of the laptop computer (4) issues a sleep command for the detection system. When detection is required again, connect to the detection device (3) again to repeat the detection work.

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