Wind turbine bolt on-line condition monitoring system and method

Abstract

The application discloses a kind of wind generating set bolt online state monitoring system and method, including stress sensing component being arranged on bolt, sensor data acquisition system being arranged in wind power generator central control room, sub alarm system being arranged in sub wind power plant central control room and total alarm system being arranged in total wind power plant central control room, wherein stress sensing component includes stress sensor, electrical connector, gap electrical connection ring plate, circle counter, data processor and signal transmitter, the cooperation setting of electrical connector, gap electrical connection ring plate and circle counter in the application, so that worker can clearly know the angle and the number of turns of bolt deflection due to loosening when maintaining loosening bolt, achieve the effect of precision reverse tightening maintenance, and through the cooperation setting of sensor data acquisition system, sub alarm system and total alarm system, vertical management mode is formed, while ensuring timely maintenance of abnormal bolt, reduce the workload of terminal personnel.

Description

Technical Field

[0001] This invention relates to the field of bolt monitoring technology for wind turbine generator sets, specifically to an online status monitoring system and method for wind turbine generator set bolts. Background Technology

[0002] With the intensification of global climate issues, the application of wind power technology has been vigorously developed and promoted. Currently, the connections of various components of wind turbines are generally made using high-strength bolts, such as the connection between blades and hub, hub and main shaft, and tower body. Throughout the 20-30 year lifespan of a wind turbine, bolt loosening due to alternating loads caused by the variability and uncertainty of wind is frequent. If loose bolts are not detected in time, they can lead to further escalation of accidents, even causing serious incidents such as turbine collapse. During normal operation of a wind turbine, the inspection cycle for high-strength bolts is generally six months to one year. This long interval means that loose bolts cannot be detected promptly, and each inspection consumes a significant amount of time, manpower, and resources. This is especially true for offshore wind turbines, which are located several kilometers inland from the coastline, making inspection inconvenient and costly. All of these factors place high demands on the reliability of bolt connections and the scientific nature of inspection and maintenance.

[0003] In the prior art, a wind turbine generator bolt online condition monitoring system and method, disclosed in publication number "CN108709724B", includes a stress washer sensor installed between the nut and the flange; a sensor data acquisition system that centrally receives monitoring data from various measuring points of a single wind turbine generator; a data processing system that analyzes the signals collected by the stress washer sensors at various parts of the wind turbine generator into the axial stress of the bolts and can convert the time-domain signal of the bolt axial stress into a frequency-domain signal; and a wind farm central monitoring system that receives stress data from each individual wind turbine generator, generates historical data, plots and compares it, and records and alarms for transient data of abnormal bolts, thereby achieving the effect of monitoring bolts used in wind turbine generators.

[0004] However, the existing technology still has significant drawbacks. For example, the existing technology can only monitor the axial stress of bolts through stress washer sensors, which cannot provide guidance for subsequent bolt repair work. Workers can only rely on intuition to carry out repairs, which reduces the effectiveness of bolt repair. In addition, the above system has a flat management structure, which makes the workload of terminal staff too heavy and prone to overlooking or forgetting a certain abnormal bolt, which poses a significant safety hazard. Summary of the Invention

[0005] The purpose of this invention is to provide an online condition monitoring system and method for wind turbine generator bolts to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An online condition monitoring system for bolts in a wind turbine generator set includes:

[0008] A stress sensing component mounted on a bolt, the stress sensing component being used to monitor the stress state of the bolt;

[0009] A sensor data acquisition system is installed in the central control room of the wind turbine. The sensor data acquisition system centrally receives the monitoring data of stress sensing components at each bolt on a single wind turbine. The sensor data acquisition system includes a wind turbine data acquisition instrument that is connected to multiple stress sensing components, and a wind turbine alarm instrument that processes the data from the wind turbine data acquisition instrument.

[0010] A sub-alarm system is installed in the central control room of a sub-wind farm. The sub-alarm system centrally receives alarm data from multiple wind turbine alarm devices within the same sub-wind farm. The sub-alarm system includes a sub-wind farm data acquisition device connected to the signals of multiple wind turbine alarm devices, and a sub-wind farm alarm device that processes the data from the sub-wind farm data acquisition device.

[0011] A central alarm system is installed in the central control room of the main wind farm. The central alarm system centrally receives alarm data from multiple sub-wind farm alarms within the same main wind farm. The central alarm system includes a main wind farm data acquisition instrument that is connected to the signals of multiple sub-wind farm alarms.

[0012] The stress sensing component includes a stress sensor embedded in the bolt and equipped with an analog switch, an electrical connector electrically connected to the stress sensor and fixed to the outer wall of the bolt end, a notched contact ring plate fixed to the bolt washer and slidably electrically connected to the electrical connector, a coil counter located at the notch of the notched contact ring plate and slidably electrically connected to the electrical connector, a data processor electrically connected to the coil counter, and a signal transmitter electrically connected to the data processor. The bolt washer is welded to the bolt connection mechanism, the notched contact ring plate is electrically connected to the data processor, and the signal transmitter is signal connected to the wind turbine data acquisition instrument. Each time the electrical connector passes through the coil counter, the number of coils counted by the coil counter increases by one. The initial number of coils counted by the coil counter electrically connected to the analog switch is zero. When the number of coils counted by the coil counter is not less than one, the analog switch closes and the stress sensor operates.

[0013] The data on the number of times the electrical connector passes through the coil counter is processed by the data processor and then transmitted to the wind turbine data acquisition instrument. The wind turbine alarm instrument processes the data on the number of times the electrical connector passes through the coil counter. If the number of times the electrical connector passes through the coil counter exceeds the preset threshold of the wind turbine alarm instrument, the wind turbine alarm instrument transmits the data on the number of times the electrical connector passes through the coil counter to the wind farm data acquisition instrument. The wind farm alarm instrument processes the data on the number of times the electrical connector passes through the coil counter. If the number of times the electrical connector passes through the coil counter exceeds the preset threshold of the wind farm alarm instrument, the wind farm alarm instrument transmits the data on the number of times the electrical connector passes through the coil counter to the main wind farm data acquisition instrument. The preset threshold of the wind farm alarm instrument is greater than the preset threshold of the wind turbine alarm instrument.

[0014] Preferably, the bolt has a monitoring groove along its axial direction for placing a stress sensor, and the space between the stress sensor and the inner wall of the monitoring groove is filled with a thermosetting epoxy resin adhesive.

[0015] Preferably, the stress sensor and the electrical connector are electrically connected via a signal transmission line.

[0016] Preferably, the stress sensor converts the internal stress load of the bolt into a 0-50mV DC voltage signal and outputs it to the data processor.

[0017] Preferably, the wind turbine data acquisition instrument, the sub-wind farm data acquisition instrument, and the total wind farm data acquisition instrument are all electrically connected to a display screen.

[0018] Preferably, the lap counter is equipped with a zeroing module.

[0019] Preferably, the repetition counter consists of a pressure sensor that slides and presses against the electrical connector, and a single-chip microcomputer that records the number of repetitions, and a conductive sheet that is slidably and electrically connected to the electrical connector is attached to the pressure sensor.

[0020] Preferably, the data processor is electrically connected to a power supply module.

[0021] A method for online condition monitoring of bolts in a wind turbine generator set, used in the aforementioned online condition monitoring system for wind turbine generator set bolts, includes the following steps:

[0022] A. The stress sensing component monitors and collects internal stress data of abnormal bolts;

[0023] B. The sensor data acquisition system centrally receives monitoring data from each abnormal bolt on a single wind turbine and transmits information about abnormal bolts that reach the alarm threshold of the wind turbine alarm to the sub-alarm system.

[0024] C. The sub-alarm system centrally receives alarm data from multiple wind turbine alarms within the same sub-wind farm and transmits information about abnormal bolts that have reached the alarm threshold of the sub-wind farm alarms to the main alarm system.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] The wind turbine generator set bolt online status monitoring system and method of the present invention, through the coordinated setting of electrical connectors, notched contact ring plates and turn counters, enables workers to clearly know the angle and number of turns of the bolt due to loosening when repairing loose bolts, achieving the effect of precise reverse tightening repair. This avoids the problems of insufficient reverse tightening resulting in unsatisfactory repair results or excessive reverse tightening damaging the bolts. Furthermore, through the coordinated setting of sensor data acquisition system, sub-alarm system and main alarm system, a vertical management mode is formed, which reduces the workload of terminal personnel while ensuring timely repair of abnormal bolts. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall system of the present invention;

[0028] Figure 2 This is a schematic diagram of the installation of the stress sensing component in this invention;

[0029] Figure 3 for Figure 2 Enlarged schematic diagram of the medium stress sensing component;

[0030] Figure 4 This is a schematic diagram showing how the stress sensing component operates when the bolts loosen in this invention.

[0031] In the diagram: 1 Bolt, 2 Bolt washer, 3 Stress sensor, 4 Electrical connector, 5 Notched contact ring plate, 6 Coil counter, 7 Data processor, 8 Signal transmitter, 9 Signal transmission line. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Please see Figure 1-4 The present invention provides a technical solution:

[0034] A wind turbine generator bolt online condition monitoring system is provided. Stress sensing components are installed on bolts 1 at various locations requiring bolt fixing, such as the blade connection, hub-to-main shaft connection, frame connection, and tower flange connection. Each stress sensing component includes a stress sensor 3 embedded within the bolt 1 and equipped with an analog switch; an electrical connector 4 electrically connected to the stress sensor 3 and fixed to the outer wall of the bolt 1 end; a notched contact ring plate 5 fixed to the bolt washer 2 and slidably electrically connected to the electrical connector 4; a coil counter 6 located at the notch of the notched contact ring plate 5 and slidably electrically connected to the electrical connector 4; a data processor 7 electrically connected to the coil counter 6; and a signal transmitter 8 electrically connected to the data processor 7. The bolt washer 2 is welded to the bolt connection mechanism, the notched contact ring plate 5 is electrically connected to the data processor 7, and the signal transmitter 8 is connected to a wind turbine generator data acquisition instrument.

[0035] In this embodiment, a monitoring groove extending axially along the end of bolt 1 is provided. The stress sensor 3 is a columnar element made of constantan wire and wrapped with an insulating layer. The analog switch is a programmable microcontroller, model XC2S150-5PQ208C, located inside the columnar element. The stress sensor 3 is inserted into the monitoring groove, and a thermosetting epoxy resin adhesive is filled between them to fix the stress sensor 3 inside bolt 1. The electrical connector 4, which is fixedly connected to the outer wall of the end of bolt 1, is electrically connected to the stress sensor 3 through a signal transmission line 9. The coil counter 6 consists of a programmable microcontroller, model XC2S150-5PQ208C, and a thin-film pressure sensor, model BW700AK. The device consists of an electrical connection and a zeroing module program that clears the recorded number of revolutions is programmed on the microcontroller. A conductive sheet is attached to the thin-film pressure sensor and is electrically connected to the electrical connector 4. The data processor 7 is a programmable microcontroller of the XC2S150-5PQ208C with an external power supply module. The power supply module is electrically connected to the signal transmitter 8, the notch-connected ring plate 5, the coil counter 6, and the conductive sheet on the coil counter 6 through the data processor 7. This allows the power supply module to supply power to the stress sensor 3, the coil counter 6, the data processor 7, and the signal transmitter 8. The signal transmitter 8 consists of a programmable microcontroller of the XC2S150-5PQ208C and a signal antenna.

[0036] After tightening bolt 1, install the coil counter 6 and the notch-connected ring plate 5 on the bolt washer 2, and make the electrical connector 4 electrically slide on the conductive plate on the coil counter 6. Press the zeroing button on the coil counter to make the number of revolutions recorded by the coil counter 6 return to zero. The coil counter 6 sends the electrical signal data of zero revolutions to the data processor 7. The data processor 7 then sends the electrical signal data of zero revolutions to the analog switch of the stress sensor 3, so that the stress sensor 3 does not work and the signal transmitter 8 does not send a signal. This avoids the problem of invalid power loss caused by the continuous operation of the stress sensor 3 in the normal bolt 1, and also reduces the monitoring workload of the staff in the wind turbine control room.

[0037] When bolt 1 loosens, bolt 1 deflects relative to bolt washer 2. The electrical connector 4 fixed to the end of bolt 1 deflects along with bolt 1, causing it to move away from the coil counter 6 and electrically connect to the notched contact ring plate 5. The separation of connector 4 from the coil counter 6 relieves the pressure on the thin-film pressure sensor. The coil counter 6 records the start of the first deflection and transmits the electrical signal data (one revolution) to the data processor 7. The data processor 7 then transmits the electrical signal data (one revolution) to the analog switch of the stress sensor 3, causing the stress sensor 3 to begin monitoring the internal load of bolt 1 and register the internal stress of the bolt. The load is converted into a 0-50mV DC voltage signal. The internal load data of bolt 1 and the number of deflection turns of bolt 1 are processed by the data processor 7 and transmitted to the sensor data acquisition system through the signal antenna of the signal transmitter 8. Similarly, after bolt 1 deflects one turn, it continues to deflect. The electrical connector 4 passes through the turn counter 6 again, which increases the number of deflection turns of bolt 1 recorded by the turn counter 6. This allows workers to clearly know the angle and number of turns of the bolt due to loosening when repairing loose bolts, achieving the effect of precise reverse tightening repair. This avoids the problem of unsatisfactory repair results due to insufficient reverse tightening or damage to the bolt due to excessive reverse tightening.

[0038] A sensor data acquisition system installed in the wind turbine control room centrally receives monitoring data from stress sensing components at each bolt on a single wind turbine. The system includes a wind turbine data acquisition unit connected to multiple stress sensing components, and a wind turbine alarm unit that processes the data from the data acquisition unit. The data acquisition unit includes a signal antenna receiving signals from a signal transmitter 8, and a display screen showing the internal load data and deflection count of bolt 1, thus alerting control room personnel to repair any abnormal bolts. The alarm unit is electrically connected to the data acquisition unit and includes a microcontroller that processes the internal load data and deflection count of bolt 1, as well as a signal connection to the wind farm data acquisition unit. The signal antenna of the wind turbine alarm device is connected to the microcontroller, which has a preset threshold for the maximum number of deflections of bolt 1. For example, in this embodiment, the threshold for the maximum number of deflections of bolt 1 set by the microcontroller of the wind turbine alarm device is 3. That is, when the number of times the electrical connector passes through the counter does not exceed 3, the wind turbine alarm device will not transmit abnormal bolt data to the wind farm data acquisition device. The staff in the wind turbine control room can handle the abnormal bolt themselves. When the number of times the electrical connector passes through the counter exceeds 3, the signal antenna of the wind turbine alarm device transmits the internal load data and deflection count data of bolt 1 to the wind farm data acquisition device, so that the wind farm control room can understand the abnormal bolt problem and urge the wind turbine control room to speed up the rectification. While ensuring that the wind farm control room can supervise and urge the work of the wind turbine control room, the workload of the staff in the wind farm control room is reduced.

[0039] A sub-alarm system is installed in the central control room of a sub-wind farm. This sub-alarm system centrally receives alarm data from multiple wind turbine alarms within the same sub-wind farm. The sub-alarm system includes a sub-wind farm data acquisition unit connected to the signals of multiple wind turbine alarms, and a sub-wind farm alarm unit that processes the data from the data acquisition unit. The sub-wind farm data acquisition unit includes a signal antenna that receives signals from the wind turbine alarms and a display screen that shows the internal load data and deflection count of bolt 1. This alerts the staff in the sub-wind farm's central control room to promptly repair any abnormal bolts. The sub-wind farm alarm unit is electrically connected to the sub-wind farm data acquisition unit and includes a microcontroller that processes the internal load data and deflection count of bolt 1, as well as a signal receiver connected to the main wind farm data acquisition unit. The sub-wind farm alarm device's microcontroller has a preset threshold for the maximum deflection number of bolts 1. In this embodiment, the threshold for the maximum deflection number of bolts 1 set by the sub-wind farm alarm device's microcontroller is 6. That is, when the number of times the electrical connector passes through the counter does not exceed 6, the sub-wind farm alarm device will not transmit abnormal bolt data to the main wind farm data acquisition device. The staff in the sub-wind farm control room can supervise the staff in the wind turbine control room themselves. When the number of times the electrical connector passes through the counter exceeds 6, the signal antenna of the sub-wind farm alarm device transmits the internal load data and deflection number data of bolt 1 to the main wind farm data acquisition device, so that the main wind farm control room can be aware of the abnormal bolt problem and urge the wind turbine control room to speed up the rectification. While ensuring that the sub-wind farm control room can supervise and urge the work of the wind turbine control room, the workload of the staff in the main wind farm control room is reduced.

[0040] A central alarm system is installed in the main wind farm control room. The central alarm system centrally receives alarm data from multiple sub-wind farm alarms within the same main wind farm. The central alarm system includes a main wind farm data acquisition unit connected to the signals of multiple sub-wind farm alarms. The main wind farm data acquisition unit includes a signal antenna that receives signals from the sub-wind farm alarms and a display screen that displays the internal load data and the number of deflection turns of bolt 1. This alerts the staff in the main wind farm control room to urge the staff in the wind turbine control room to repair abnormal bolts in a timely manner. This forms a vertical management model that reduces the workload of terminal personnel while ensuring timely repair of abnormal bolts.

[0041] A method for online condition monitoring of bolts in a wind turbine generator set, used in the aforementioned online condition monitoring system for wind turbine generator set bolts, includes the following steps:

[0042] A. The stress sensing component monitors and collects internal stress data of abnormal bolts;

[0043] B. The sensor data acquisition system centrally receives monitoring data from each abnormal bolt on a single wind turbine and transmits information about abnormal bolts that reach the alarm threshold of the wind turbine alarm to the sub-alarm system.

[0044] C. The sub-alarm system centrally receives alarm data from multiple wind turbine alarms within the same sub-wind farm and transmits information about abnormal bolts that have reached the alarm threshold of the sub-wind farm alarms to the main alarm system.

[0045] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An online condition monitoring system for bolts in a wind turbine generator set, characterized in that, include: A stress sensing component mounted on a bolt, the stress sensing component being used to monitor the stress state of the bolt; A sensor data acquisition system is installed in the central control room of the wind turbine. The sensor data acquisition system centrally receives the monitoring data of stress sensing components at each bolt on a single wind turbine. The sensor data acquisition system includes a wind turbine data acquisition instrument that is connected to multiple stress sensing components, and a wind turbine alarm instrument that processes the data from the wind turbine data acquisition instrument. A sub-alarm system is installed in the central control room of a sub-wind farm. The sub-alarm system centrally receives alarm data from multiple wind turbine alarm devices within the same sub-wind farm. The sub-alarm system includes a sub-wind farm data acquisition device connected to the signals of multiple wind turbine alarm devices, and a sub-wind farm alarm device that processes the data from the sub-wind farm data acquisition device. A central alarm system is installed in the central control room of the main wind farm. The central alarm system centrally receives alarm data from multiple sub-wind farm alarms within the same main wind farm. The central alarm system includes a main wind farm data acquisition instrument that is connected to the signals of multiple sub-wind farm alarms. The stress sensing component includes a stress sensor embedded in the bolt and equipped with an analog switch, an electrical connector electrically connected to the stress sensor and fixed to the outer wall of the bolt end, a notched contact ring plate fixed to the bolt washer and slidably electrically connected to the electrical connector, a coil counter located at the notch of the notched contact ring plate and slidably electrically connected to the electrical connector, a data processor electrically connected to the coil counter, and a signal transmitter electrically connected to the data processor. The bolt washer is welded to the bolt connection mechanism, the notched contact ring plate is electrically connected to the data processor, and the signal transmitter is signal connected to the wind turbine data acquisition instrument. Each time the electrical connector passes through the coil counter, the number of coils counted by the coil counter increases by one. The initial number of coils counted by the coil counter electrically connected to the analog switch is zero. When the number of coils counted by the coil counter is not less than one, the analog switch closes and the stress sensor operates. The data on the number of times the electrical connector passes through the coil counter is processed by the data processor and then transmitted to the wind turbine data acquisition instrument. The wind turbine alarm instrument processes the data on the number of times the electrical connector passes through the coil counter. If the number of times the electrical connector passes through the coil counter exceeds the preset threshold of the wind turbine alarm instrument, the wind turbine alarm instrument transmits the data on the number of times the electrical connector passes through the coil counter to the wind farm data acquisition instrument. The wind farm alarm instrument processes the data on the number of times the electrical connector passes through the coil counter. If the number of times the electrical connector passes through the coil counter exceeds the preset threshold of the wind farm alarm instrument, the wind farm alarm instrument transmits the data on the number of times the electrical connector passes through the coil counter to the main wind farm data acquisition instrument. The preset threshold of the wind farm alarm instrument is greater than the preset threshold of the wind turbine alarm instrument.

2. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The bolt has a monitoring groove along its axial direction for placing a stress sensor, and the space between the stress sensor and the inner wall of the monitoring groove is filled with a thermosetting epoxy resin adhesive.

3. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The stress sensor and the electrical connector are electrically connected via a signal transmission line.

4. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The stress sensor converts the internal stress load of the bolt into a 0-50mV DC voltage signal and outputs it to the data processor.

5. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The wind turbine data acquisition instrument, the sub-wind farm data acquisition instrument, and the total wind farm data acquisition instrument are all electrically connected to a display screen.

6. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The lap counter is equipped with a zeroing module.

7. The online condition monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The lap counter consists of a pressure sensor that slides and presses against the electrical connector, and a single-chip microcomputer that records the number of laps. A conductive sheet that slides and is electrically connected to the electrical connector is attached to the pressure sensor.

8. The online status monitoring system for wind turbine generator bolts according to claim 1, characterized in that: The data processor is electrically connected to a power module.

9. A method for online condition monitoring of bolts in a wind turbine generator set, used in the online condition monitoring system for bolts in a wind turbine generator set as described in any one of claims 1-8, characterized in that, Includes the following steps: A. The stress sensing component monitors and collects internal stress data of abnormal bolts; B. The sensor data acquisition system centrally receives monitoring data from each abnormal bolt on a single wind turbine and transmits information about abnormal bolts that reach the alarm threshold of the wind turbine alarm to the sub-alarm system. C. The sub-alarm system centrally receives alarm data from multiple wind turbine alarms within the same sub-wind farm and transmits information about abnormal bolts that have reached the alarm threshold of the sub-wind farm alarms to the main alarm system.

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