Condition monitoring method of mechanical brake of hydro-generator based on multi-source data

Abstract

This method for monitoring the mechanical brake status of a hydro-turbine generator based on multiple data sources makes judgments based on data from the mechanical brake status monitoring system. The system includes an information acquisition module, which collects the status of the displacement sensor and proximity switch on the mechanical brake and transmits it to the information processing module. The information processing module processes the status data and transmits the results to the output module, which displays the results on the display module. This method utilizes analog signals collected by the displacement sensor and position status signal data collected by the non-contact proximity switch for monitoring and judgment, surpassing the traditional single-switch signal monitoring method. This method achieves digital monitoring of the mechanical brake's full travel range, achieving 100% mechanical brake actuation accuracy. This allows for more accurate judgment of the brake's status, improving the diagnostic and control capabilities of the mechanical brake control system.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical automatic control of hydropower stations, and in particular to a method for monitoring the state of a hydraulic generator mechanical brake based on multiple data sources. Background Art

[0002] The turbine generator brake (commonly known as the wind gate) is a key component in the unit's mechanical braking system and a crucial piece of equipment in hydropower plants. Stable and reliable operation is essential to ensure the safe operation of the unit. Currently, mechanical brake position monitoring uses a crank-type position switch, which converts the wind gate's mechanical displacement into a switching electrical signal. This signal is then sent to the unit's LCU for startup and shutdown process decisions, providing a basis for operator control. However, this approach presents the following issues:

[0003] 1. The crank-type position switch has a mechanical dead zone. After long-term operation, the dead zone gradually becomes larger, which will cause false operation or refusal to operate, directly affecting the success rate of starting and stopping the unit. In severe cases, it will affect the safe operation of the unit.

[0004] 2. The existing position monitoring method uses two pairs of auxiliary nodes of a contact position switch to represent the lifting or lowering status respectively. When the position switch fails, the position status of the mechanical brake cannot be identified, and there is a blind spot in the equipment status identification; some power plants use two crank-type position switch nodes to represent the lifting or lowering status respectively. The monitoring method is relatively simple, and the status judgment logic is simple. It only monitors the switch status and does not have the full-stroke digital monitoring function of the wind brake lifting and lowering. It is currently unable to truly reflect the action displacement and action status of the mechanical brake.

[0005] 3. Currently, the mechanical brake remains in the down position after the start-up and shutdown processes are completed. This does not provide reasonable output control instructions based on the actual operating conditions of the unit, allowing the mechanical brake to fully function. In particular, when the unit needs to be shut down and prevent malfunction, maintenance personnel must manually control the unit from the on-site control cabinet to take measures.

[0006] Therefore, the brake damper is not just a simple contact signal return and output control instruction. With the development of digitalization and intelligence, more consideration should be given to the digitization of mechanical brake displacement and status monitoring to meet the needs of smart power plant construction. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a method for monitoring the status of the mechanical brake of a hydro-turbine generator based on multiple data sources, which can more accurately judge the status of the mechanical brake, improve the monitoring reliability, realize the full-stroke digital monitoring function of the mechanical brake, and more realistically and intuitively display the action displacement and action status of the mechanical brake, thereby avoiding damage to the unit caused by unsuccessful mechanical brake operation.

[0008] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0009] A method for monitoring the mechanical brake status of a hydro-turbine generator based on multiple data sources is provided. The method makes judgments based on data from a mechanical brake status monitoring system. The mechanical brake status monitoring system includes an information acquisition module. The information acquisition module acquires the status of a displacement sensor and a proximity switch on the mechanical brake and sends the information to an information processing module. The information processing module processes the status data and sends the result to an output module. The output module displays the result on a display module. The specific steps of the method for monitoring the mechanical brake status are as follows:

[0010] Step 1: According to the load output and start-up and shutdown plan of the power plant units, the operating conditions of the hydropower units in the power plant are obtained, and the corresponding state of the mechanical brake under the current operating conditions of the units is determined;

[0011] Step 2: Predict the actual output state of the mechanical brake based on the collected displacement signal, proximity switch action signal, and the set control method;

[0012] Step 3: Determine that the unit is in standby mode and the output state of the mechanical brake is in the jacking state. Output the mechanical brake jacking control command, perform mechanical brake jacking control, and execute the jacking state control method judgment.

[0013] The specific control method is as follows: when the switch value of the proximity switch and the analog value collected data of the displacement sensor meet all the threshold conditions of lifting, the output of the mechanical brake is the lifting state; when the switch value or the analog value collected data meet any one of the judgment conditions of falling, the output of the mechanical brake is the falling state;

[0014] The specific execution process is:

[0015] Step 1: Determine whether the action amount Sn of the mechanical brake proximity switch is greater than the preset jacking value Sq of the proximity switch, that is, Sn > Sq, where n is the number of mechanical brakes and whether the n groups of parameter states all meet the conditions; if the requirements are not met, then determine whether any group meets the conditions when Sn < Sq and Sn < Slx; where n = 1 to j; j is an integer adjusted according to the actual on-site configuration, and Slx is the preset falling value of the proximity switch; if the requirements are met, output the state of the mechanical brake in the current working condition as the falling state, which does not conform to the unit operating condition; otherwise, it means that the mechanical brake does not act in place or during the jacking process, and continue to wait to execute Step 1; if the requirements are met, then execute Step 2;

[0016] Step 2: Determine whether the displacement change amount Ln of the mechanical brake is greater than the preset jacking value Lq, that is, Ln > Lq, where n = 1 to j and whether the n groups of state parameters all meet the conditions; if the requirements are met, output the state of the mechanical brake as the jacking state, which conforms to the unit operating condition; if the requirements are not met, then execute Step 3;

[0017] Step 3: Determine whether any group meets the conditions when Ln < Lq and Ln < Llx; where n = 1 to j, and Llx is the preset falling value of the displacement change amount of the mechanical brake; if the requirements are met, output the state of the mechanical brake in the current working condition as the falling state, which does not conform to the unit operating condition; otherwise, wait to execute Step 1;

[0018] Step 4: Determine that the unit working condition is the grid-connected operation state, the output state of the mechanical brake should be the falling state, output the falling control command of the mechanical brake, perform the falling control of the mechanical brake, and execute the judgment of the control method in the falling state;

[0019] The specific control method is: when the switch quantity and analog quantity acquisition data meet all the judgment threshold conditions for falling, then output the mechanical brake as the falling state; when the switch quantity or analog quantity meets any one of the jacking threshold conditions, then output the mechanical brake as the jacking state;

[0020] The specific execution process is:

[0021] Step 1: Determine whether the action amount Sn of the mechanical brake proximity switch is less than the preset falling value Slx of the proximity switch, that is, Sn < Slx, where n is the number of mechanical brakes and whether the n groups of parameter states all meet the conditions; if the requirements are not met, then determine whether any group meets the conditions when Sn > Sq and Sn > Slx; where n = 1 to j; j is an integer adjusted according to the actual on-site configuration; if the requirements are met, output the state of the mechanical brake in the current working condition as the jacking state, which does not conform to the unit operating condition; otherwise, it means that the mechanical brake does not act in place or during the falling process, and continue to wait to execute Step 1; if the requirements are met, then execute Step 2;

[0022] Step 2: Determine whether the displacement change amount Ln of the mechanical brake is less than the preset falling value Llx, that is, Ln < Llx, and whether all n sets of state parameters meet the conditions; where n = 1 to j; if the requirements are met, the output state of the mechanical brake is the falling state, which conforms to the unit operating condition; if the requirements are not met, proceed to Step 3.

[0023] Step 3: Determine whether any one of Ln > Ldq and Ln > Llx meets the conditions; where n = 1 to j; if the requirements are met, the output state of the mechanical brake under the current condition is the jacking state, which does not conform to the unit operating condition; otherwise, wait to execute Step 1. [[ID=⑥]]

[0024] [[ID=⑦]]The above unit operating conditions are divided into the shutdown standby state and the grid-connected operation state, and the unit operating condition signal is taken from the unit monitoring system database. [[ID=⑧]] [[ID=⑨]]

[0025] [[ID=⑩]]When the above unit operating condition is the shutdown standby state, the output state of the mechanical brake corresponds to the jacking state, and the jacking control command of the mechanical brake is output. The command is automatically issued by the shutdown process of the monitoring system and can also be manually controlled and issued by the mechanical brake cabinet during commissioning or maintenance. [[ID=⑪]] [[ID=⑫]]

[0026] [[ID=⑬]]When the unit operating condition is the shutdown standby state, the criterion for the jacking state of the mechanical brake is that the action amount Sn of the proximity switch of the mechanical brake is greater than the preset jacking value Sdq of the proximity switch; at the same time, the displacement change amount Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, both Ln > Ldq and Sn > Sdq are satisfied. [[ID=⑭]] [[ID=⑮]]

[0027] [[ID=⑯]]When the above unit operating condition is the grid-connected operation state, the output state of the mechanical brake corresponds to the falling state, and the falling control command of the mechanical brake is output. The command is automatically issued by the startup process of the monitoring system and can also be manually controlled and issued by the mechanical brake cabinet during commissioning or maintenance. [[ID=⑰]] [[ID=⑱]]

[0028] [[ID=⑲]]When the unit operating condition is the grid-connected operation state, the criterion for the falling state of the mechanical brake is that the action amount Sn of the mechanical brake is less than the preset falling value Slx of the proximity switch; at the same time, the displacement change amount Ln of the mechanical brake is less than the preset falling value Llx, that is, both Sn < Slx and Ln < Llx are satisfied. [[ID=⑳]] [[ID=㉑]]

[0029] [[ID=㉒]]The above digital quantity signals use non-contact proximity switch signals, and their sensing distance is adjusted within the effective measurement range. The effective measurement range is 3 to 12 mm; the non-contact proximity switch is fixed on the mounting bracket of the base of the mechanical brake body, and the movable rod of the proximity switch is fixed at one end of the brake plate of the mechanical brake and moves synchronously with the brake plate of the mechanical brake. [[ID=㉓]] [[ID=㉔]]

[0030] The above-mentioned mechanical brake action amount Sn is the distance between the lower end surface of the proximity switch movable rod and the top end of the proximity switch contact; when the mechanical brake action amount Sn is less than the preset falling value Slx of the proximity switch, that is, Sn < Slx indicates that the proximity switch has actuated, that is, the mechanical brake is in the falling state; when the mechanical brake action amount Sn is greater than the preset falling value Sdq of the proximity switch, that is, Sn > Sdq indicates that the proximity switch has reset, that is, the mechanical brake is in the state of resetting the falling state.

[0031] The above-mentioned analog signal uses the displacement amount collected by the displacement sensor, and its range should meet the maximum working stroke of the mechanical brake brake plate. The maximum working stroke is 30 - 50 mm; the displacement sensor is installed on the mounting bracket of the mechanical brake body base, and the displacement sensor connecting rod is fixed at one end of the mechanical brake brake plate and moves synchronously with the mechanical brake brake plate.

[0032] The above-mentioned mechanical brake displacement change amount Ln is the distance that the displacement sensor connecting rod moves, that is, the distance that the mechanical brake brake plate moves; when the mechanical brake displacement change amount Ln is less than the preset falling value Llx, that is, Ln < Llx, it indicates that the displacement sensor has contracted, that is, the mechanical brake is in the falling state; when the mechanical brake displacement change amount Ln is greater than the preset jacking value Ldq, that is, Ln > Ldq, it indicates that the displacement sensor has stretched, that is, the mechanical brake is in the jacking state.

[0033] The functions of each module in the above-mentioned mechanical brake status monitoring system are as follows:

[0034] The signal acquisition module is used to obtain the load output and start / stop plan of the power plant unit, and obtain the operating conditions of the power plant hydro-generator unit; obtain the displacement signal of the mechanical brake and the proximity switch action signal;

[0035] The information processing module is used to determine the应有状态 (should-be state) of the mechanical brake according to different operating conditions of the unit; and process the displacement signal of the mechanical brake and the proximity switch action signal according to the established control method, and output the corresponding control instructions; when the unit condition is the shutdown standby state, execute the control strategy judgment for processing the jacking state; when the unit condition is the grid-connected operation state, execute the control strategy judgment for processing the falling state;

[0036] The output module is used to monitor the system and output the control instructions of the mechanical brake; when the unit condition is the shutdown standby state, the output state of the mechanical brake should be the jacking state, output the mechanical brake jacking control instruction, and perform the mechanical brake jacking control; when the unit condition is the grid-connected operation state, the output state of the mechanical brake should be the falling state, output the mechanical brake falling control instruction, and perform the mechanical brake falling control;

[0037] The display module is used to display the current operating conditions of the unit and the action status and displacement change amount information of the mechanical brake. It should be noted that the term "应有状态" in the original text is not clear. I have translated it as "should-be state" for the purpose of literal translation. It may need to be adjusted according to the specific context to a more accurate expression.

[0038] The present invention provides a method for monitoring the status of a hydraulic generator mechanical brake based on multiple data sources, which breaks through the traditional contact position switch monitoring method and adopts analog signals collected by displacement sensors and position status signal data collected by non-contact proximity switches for monitoring and judgment, breaking through the traditional single switch signal monitoring method; the method of the present invention realizes the full-stroke digital monitoring function of the mechanical brake, and the action accuracy of the mechanical brake is as high as 100%, which can more accurately judge the status of the brake and improve the diagnosis and control level of the status of the mechanical brake control system; the method of the present invention optimizes the mechanical brake status monitoring logic and control strategy on the original basis, adapts to different operating conditions of the unit, and outputs different mechanical brake control instructions, which more accurately judges the status of the mechanical brake, improves monitoring reliability, and more realistically and intuitively displays the action displacement and action status of the mechanical brake, avoiding unit damage caused by unsuccessful mechanical brake operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The present invention will be further described below with reference to the accompanying drawings and examples:

[0040] Figure 1 The invention provides a hydraulic generator mechanical brake state monitoring system based on multi-source data;

[0041] Figure 2 The flowchart of the method for monitoring the condition of the mechanical brake of a hydro-generator based on multi-source data is shown;

[0042] Figure 3 A method for monitoring the mechanical brake condition of a hydro-generator based on multi-source data;

[0043] Figure 4 It is the actual measured value of the proximity switch sensing distance when the mechanical brake is dropped and lifted;

[0044] Figure 5 It is the actual measured value of the displacement sensor when the mechanical brake is dropped and lifted;

[0045] Figure 6 This is a full-stroke action record table of the mechanical brake displacement sensor of the left bank unit in the embodiment;

[0046] Figure 7 This is a full-stroke action record table for the mechanical brake displacement sensor of the right bank unit in the embodiment. DETAILED DESCRIPTION

[0047] like Figure 1-3As shown in [figure], a method for monitoring the mechanical brake state of a hydrogenerator based on multiple data sources. The mechanical brake state monitoring method makes a judgment based on the data of the mechanical brake state monitoring system. The mechanical brake state monitoring system includes an information acquisition module, which collects the states of displacement sensors and proximity switches on the mechanical brake and sends them to the information processing module. The information processing module processes the state data and sends the results to the output module. The output module displays the results on the display module. The specific steps of the mechanical brake state monitoring method are as follows:

[0048] Step1. According to the load output and start-stop plan of the power plant unit, obtain the operating conditions of the hydroelectric unit of the power plant, and determine the state corresponding to the mechanical brake under the current operating conditions of the unit;

[0049] Step2. According to the collected displacement signal, proximity switch action signal, and the set control method, predict the actual output state of the mechanical brake;

[0050] Step3. When the unit condition is the shutdown standby state, the output state of the mechanical brake should be the jacking state. Output the mechanical brake jacking control command, perform the mechanical brake jacking control, and execute the control method judgment of the jacking state;

[0051] The specific control method is as follows: When the digital quantity of the proximity switch and the analog quantity acquisition data of the displacement sensor meet the threshold conditions for full jacking, the output mechanical brake is in the jacking state; when the data collected by the digital quantity or analog quantity meets any one of the falling judgment conditions, the output mechanical brake is in the falling state;

[0052] The specific execution process is as follows:

[0053] The first step: Judge whether the action quantity Sn of the proximity switch of the mechanical brake is greater than the preset jacking value Sdq of the proximity switch, that is, Sn > Sdq, where n is the number of mechanical brakes, and whether all n sets of parameter states meet the conditions; if the requirements are not met, judge whether Sn < Sdq and Sn < Slx, and whether any one set meets the conditions; where n = 1 to j; j is an integer, adjusted according to the actual on-site configuration, and Slx is the preset falling value of the proximity switch; if the requirements are met, output the state of the mechanical brake under the current working condition as the falling state, which does not conform to the operating conditions of the unit; otherwise, it means that the mechanical brake does not act in place or during the jacking process, and continue to wait to execute the first step; if the requirements are met, execute the second step;

[0054] The second step: Judge whether the displacement change quantity Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, Ln > Ldq, where n = 1 to j, and whether all n sets of state parameters meet the conditions; if the requirements are met, output the state of the mechanical brake as the jacking state, which conforms to the operating conditions of the unit; if the requirements are not met, execute the third step;

[0055] Step 3: Determine whether any group satisfies the condition that Ln < Ldq and Ln < Llx, where n = 1 to j, and Llx is the preset falling value of the displacement change of the mechanical brake; if the requirement is satisfied, output that the state of the mechanical brake under the current working condition is the falling state, which does not conform to the unit operation condition; otherwise, wait to execute Step 1.

[0056] Step 4: Determine that the unit working condition is the grid-connected operation state, the output state of the mechanical brake should be the falling state, output the mechanical brake falling control command, perform the mechanical brake falling control, and execute the judgment of the control method in the falling state.

[0057] The specific control method is: when the collected data of switch quantities and analog quantities meet all the judgment threshold conditions for falling, output that the mechanical brake is in the falling state; when any one of the switch quantities or analog quantities meets the threshold condition for jacking up, output that the mechanical brake is in the jacking-up state.

[0058] The specific execution process is:

[0059] Step 1: Determine whether the action quantity Sn of the proximity switch of the mechanical brake is less than the preset falling value Slx of the proximity switch, that is, Sn < Slx, where n is the number of mechanical brakes, and whether the n groups of parameter states all meet the conditions; if the requirement is not met, then determine whether Sn > Sq and Sn > Slx, whether any group meets the conditions; where n = 1 to j; j is an integer, adjusted according to the actual on-site configuration; if the requirement is met, output that the state of the mechanical brake under the current working condition is the jacking-up state, which does not conform to the unit operation condition; otherwise, it means that the mechanical brake does not act in place or is in the falling process, and continue to wait to execute Step 1; if the requirement is met, then execute Step 2.

[0060] Step 2: Determine whether the displacement change quantity Ln of the mechanical brake is less than the preset falling value Llx, that is, Ln < Llx, and whether the n groups of state parameters all meet the conditions; where n = 1 to j; if the requirement is met, output that the state of the mechanical brake is the falling state, which conforms to the unit operation condition; if the requirement is not met, then execute Step 3.

[0061] Step 3: Determine whether any group satisfies the condition that Ln > Ldq and Ln > Llx; where n = 1 to j; if the requirement is met, output that the state of the mechanical brake under the current working condition is the jacking-up state, which does not conform to the unit operation condition; otherwise, wait to execute Step 1.

[0062] The above unit working conditions are divided into the shutdown standby state and the grid-connected operation state, and the unit working condition signal is taken from the unit monitoring system database.

[0063] When the above unit operating condition is the shutdown standby state, the output state of the mechanical brake corresponds to the jacking state, and the mechanical brake jacking control command is output. The command is automatically issued by the shutdown process of the monitoring system and can also be manually controlled and issued by the mechanical brake cabinet during commissioning or maintenance;

[0064] When the unit operating condition is the shutdown standby state, the criterion for the mechanical brake jacking state is that the action quantity Sn of the mechanical brake proximity switch is greater than the preset jacking value Sdq of the proximity switch; at the same time, the displacement change quantity Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, both Ln>Ldq and Sn>Sdq are satisfied.

[0065] When the above unit operating condition is the grid-connected operation state, the output state of the mechanical brake corresponds to the falling state, and the mechanical brake falling control command is output. The command is automatically issued by the startup process of the monitoring system and can also be manually controlled and issued by the mechanical brake cabinet during commissioning or maintenance;

[0066] When the unit operating condition is the grid-connected operation state, the criterion for the mechanical brake falling state is that the action quantity Sn of the mechanical brake is less than the preset falling value Slx of the proximity switch; at the same time, the displacement change quantity Ln of the mechanical brake is less than the preset falling value Llx, that is, both Sn<Slx and Ln<Llx are satisfied.

[0067] The above digital input signal adopts a non-contact proximity switch signal, and its sensing distance is adjusted within the effective measurement range. The effective measurement range is 3 - 12 mm; the non-contact proximity switch is fixed on the mounting bracket of the mechanical brake body base, and the proximity switch movable rod is fixed at one end of the mechanical brake brake plate and moves synchronously with the mechanical brake brake plate.

[0068] The action quantity Sn of the above mechanical brake is the distance between the lower end face of the proximity switch movable rod and the top end of the proximity switch contact; when the action quantity Sn of the mechanical brake is less than the preset falling value Slx of the proximity switch, that is, Sn<Slx indicates that the proximity switch has actuated, that is, the mechanical brake is in the falling state; when the action quantity Sn of the mechanical brake is greater than the preset falling value Sdq of the proximity switch, that is, Sn>Sdq indicates that the proximity switch has reset, that is, the mechanical brake is in the falling state reset.

[0069] The closer the value of Slx is to the on-site setting value of the sensing distance when the proximity switch actuates, the higher the accuracy of the proximity switch actuation; the closer the value of Slx is to or greater than the effective sensing distance value ±5 mm, the higher the sensitivity of the proximity switch; generally, the on-site setting value of Slx is taken as the middle value of the effective sensing distance, and the value of Sdq is taken as the maximum value of the effective sensing distance +5 mm, indicating that the mechanical brake is fully and completely jacked up.

[0070] The analog signal mentioned above is the displacement collected by a displacement sensor, and its range should meet the maximum working stroke of the brake plate of the mechanical brake. The maximum working stroke is 30 - 50 mm. The displacement sensor is installed on the mounting bracket at the base of the mechanical brake body, and the displacement sensor connecting rod is fixed to one end of the brake plate of the mechanical brake and moves synchronously with the brake plate of the mechanical brake.

[0071] The displacement change amount Ln of the above-mentioned mechanical brake is the distance that the displacement sensor connecting rod moves, that is, the distance that the brake plate of the mechanical brake moves. When the displacement change amount Ln of the mechanical brake is less than the preset falling value Llx, that is, Ln < Llx, it means that the displacement sensor has shrunk, that is, the mechanical brake is in the falling state. When the displacement change amount Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, Ln > Ldq, it means that the displacement sensor has stretched, that is, the mechanical brake is in the jacking state.

[0072] The closer the value of Llx is to or less than the on-site setting value Slx when the proximity switch operates, it indicates that the lower limit detection ability of the displacement sensor is strong and it can fully monitor that the mechanical brake has completely fallen. The closer the value of Ldq is to or greater than the on-site setting value Sdq when the proximity switch returns, it indicates that the upper limit detection ability of the displacement sensor is strong and it can fully monitor that the mechanical brake has completely jacked up. Generally, the value of Llx is taken as Slx - 2 mm, and the value of Ldq is taken as Sdq + 2 mm.

[0073] The action stroke range of the mechanical brake is determined according to the braking demand of the generator rotor of the main engine factory. Generally, for a certain power plant, the maximum stroke of the mechanical brake of the left-bank unit is 40 mm, and the maximum stroke of the mechanical brake of the right-bank unit is 50 mm.

[0074] Embodiment:

[0075] A method for monitoring the state of a mechanical brake of a hydro-generator based on multi-source data, as Figure 2 , the method includes:

[0076] Step S1: According to the load output and start-stop plan of the power plant unit, obtain the operating conditions of the hydro-generator unit of the power plant and determine the normal state that the mechanical brake should have under the current operating conditions of the unit. For a certain power plant, the planned load for the day is 600 MW, and it is necessary to stop the No. 1 and No. 2 units and operate the No. 3 and No. 4 units. Among them, the No. 1 unit needs to be in the standby state for shutdown, so the mechanical brake should be in the jacking state under the current working conditions.

[0077] Step S2: According to the collected displacement signal, proximity switch action signal and the established control strategy, predict the actual output state of the mechanical brake. When the mechanical brake is in the falling state under the standby state for shutdown of this unit, the measured values of the displacement sensors L1 - L24 and proximity switches S1 - S24 of the ZD01 - ZD24 groups of mechanical brakes are respectively shown in Figure 4 and Figure 5 As shown, when the displacement sensors L1 to L24 operate, the set value of the induction distance is 4.5 ± 0.1 mm, and the maximum error value of the induction distance when the proximity switches operate is 0.12 mm, both meeting the standard requirement that the error value is less than 2 mm; when the proximity switches S1 to S24 operate, the set value of the induction distance is 6.5 ± 0.1 mm, and the error value of the induction distance when the displacement sensors operate is 0.11 mm, both meeting the standard requirement that the error value is less than 3 mm;

[0078] Note: When the displacement sensors L1 to L24 operate, the set value of the induction distance is 4.5 ± 0.1 mm, which is greater than the set value of the induction distance of 6.5 ± 0.1 mm when the proximity switches S1 to S24 operate, because the sampling accuracy and real-time performance of the displacement sensors are higher than those of the proximity switches;

[0079] Step S3: Determine that the unit condition is the shutdown standby state. The output state of the mechanical brake should be the jacked-up state. Output the mechanical brake jacking control command, perform the mechanical brake jacking control, and execute the control strategy judgment of the jacked-up state;

[0080] When Unit 1 is in the shutdown standby state, the monitoring system should output the mechanical brake jacking control command and execute the jacking control. According to Figure 4 and Figure 5 Data shows that when the measured value of the induction distance when the displacement sensors L1 to L24 operate is greater than the set value, and the measured value of the induction distance when the proximity switches S1 to S24 operate is greater than the set value, it is judged that the mechanical brake is in the jacked-up state under the shutdown standby state of the unit;

[0081] The specific execution process is as follows: As shown in the figure below, in the first step, judge whether the action amount Sn of the mechanical brake proximity switch is greater than the preset jacking-up value Sdq of the proximity switch, that is, Sn > Sdq (n is the number of mechanical brakes), and whether the n groups of parameter states all meet the conditions. If the requirements are not met, judge whether any group meets the conditions when Sn < Sdq and Sn < Slx, (n = 1 to j; j is an integer, adjusted according to the actual on-site configuration); if the requirements are met, output the state of the mechanical brake in the current condition as the lowered state, which does not conform to the unit operation condition; otherwise, it means that the mechanical brake does not act in place or during the jacking-up process, and continue to wait and execute the first step; if the requirements are met, execute the second step;

[0082] In the second step, judge whether the displacement change amount Ln of the mechanical brake is greater than the preset jacking-up value Ldq, that is, Ln > Ldq, (n = 1 to j), and whether the n groups of state parameters all meet the conditions; if the requirements are met, output the state of the mechanical brake as the jacked-up state, which conforms to the unit operation condition; if the requirements are not met, execute the third step;

[0083] Step 3: Determine whether any group satisfies the condition that Ln < Ldq and Ln < Llx (n = 1 to j); if the requirement is met, output that the mechanical brake state under the current working condition is the lowered state, which does not conform to the unit operation condition; otherwise, wait to execute Step 1.

[0084] Step S4: Determine that the unit working condition is the grid-connected operation state. The output state of the mechanical brake should be the lowered state. Output the mechanical brake lowering control command, perform the mechanical brake lowering control, and execute the control strategy judgment for the lowered state.

[0085] When Unit 3 is in the grid-connected operation state, the monitoring system should output the mechanical brake lowering control command and perform the lowering control; according to Figure 4 and Figure 5 Data shows that when the measured induction spacing values of displacement sensors L1 to L24 during their actions are less than the set value, and the measured induction spacing values of proximity switches S1 to S24 during their actions are less than the set value, it is judged that the mechanical brake is already in the lowered state under the unit shutdown standby state.

[0086] The specific execution process is as follows: As shown in the figure below, in Step 1, judge whether the action amount Sn of the mechanical brake proximity switch is less than the preset lowered value Slx of the proximity switch, that is, Sn < Slx (n is the number of mechanical brakes), and whether the n-group parameter states all meet the conditions; if the requirement is not met, then judge whether Sn > Sdq and Sn > Slx, (n = 1 to j; j is an integer, adjusted according to the actual on-site configuration) any group meets the conditions; if the requirement is met, output that the mechanical brake state under the current working condition is the jacked-up state, which does not conform to the unit operation condition; otherwise, it means that the mechanical brake does not act in place or during the lowering process, and continue to wait to execute Step 1. If the requirement is met, execute Step 2.

[0087] In Step 2, judge whether the displacement change amount Ln of the mechanical brake is less than the preset lowered value Llx, that is, Ln < Llx, (n = 1 to j), and whether the n-group state parameters all meet the conditions. If the requirement is met, output that the mechanical brake state is the lowered state, which conforms to the unit operation condition. If the requirement is not met, execute Step 3.

[0088] In Step 3, judge whether any group satisfies the condition that Ln > Ldq and Ln > Llx (n = 1 to j). If the requirement is met, output that the mechanical brake state under the current working condition is the jacked-up state, which does not conform to the unit operation condition; otherwise, wait to execute Step 1.

[0089] On the other hand of the present invention, a mechanical brake state monitoring system for a hydro-generator based on multi-source data is provided, as Figure 1 The system includes:

[0090] The signal acquisition module is used to obtain the load output and start-up and shutdown plans of the power plant units, the operating conditions of the hydropower units in the power plant, and the displacement signal of the mechanical brake and the action signal of the proximity switch.

[0091] The information processing module determines the proper state of the mechanical brake based on the unit's operating conditions. It processes the mechanical brake's displacement signal and proximity switch actuation signal using a pre-defined control strategy and outputs corresponding control instructions. When the unit is in standby mode, the control strategy for the jacking-up state is executed. When the unit is in grid-connected operation, the control strategy for the lowered state is executed.

[0092] The output module is used to monitor the system's output of mechanical brake control commands. When the unit is in standby mode, the mechanical brake output state should be in the "up" state, and the "up" control command should be output to activate the mechanical brake. When the unit is in grid-connected operation, the mechanical brake output state should be in the "down" state, and the "down" control command should be output to activate the mechanical brake.

[0093] The display module is used to display the current operating conditions of the unit and the action status and displacement change information of the mechanical brake.

Claims

1. A method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources, characterized in that: The mechanical brake status monitoring method makes a judgment based on the data of the mechanical brake status monitoring system. The mechanical brake status monitoring system includes an information acquisition module. The information acquisition module collects the status of the displacement sensor and proximity switch on the mechanical brake and sends it to the information processing module. The information processing module processes the status data and sends the result to the output module. The output module displays the result on the display module. The specific steps of the mechanical brake status monitoring method are as follows: Step1: Obtain the operating conditions of the power plant's hydro-generator units according to the load output and start-stop plan of the power plant units, and determine the corresponding status of the mechanical brake under the current operating conditions of the units; Step2: Predict the actual output status of the mechanical brake according to the collected displacement signal, proximity switch action signal, and the set control method; Step3: When the unit condition is the shutdown standby state, the output status of the mechanical brake should be the jacking state. Output the mechanical brake jacking control instruction, perform the mechanical brake jacking control, and execute the control method judgment of the jacking state; The specific control method is: when the digital quantity of the proximity switch and the analog quantity of the displacement sensor meet the threshold conditions for full jacking, the output mechanical brake is in the jacking state; when the data collected for the digital quantity or analog quantity meets any one of the falling judgment conditions, the output mechanical brake is in the falling state; The specific execution process is: The first step: Judge whether the action quantity Sn of the mechanical brake proximity switch is greater than the preset jacking value Sdq of the proximity switch, that is, Sn > Sdq, where n is the number of mechanical brakes, and whether all n sets of parameter states meet the conditions; if the requirements are not met, judge whether Sn < Sdq and Sn < Slx, and whether any one set meets the conditions; where n = 1~j; j is an integer, adjusted according to the actual on-site configuration, and Slx is the preset falling value of the proximity switch; If the requirements are met, output the mechanical brake status under the current working condition as the falling state, which does not conform to the unit operating conditions; otherwise, it means that the mechanical brake does not act in place or during the jacking process, and continue to wait to execute the first step; if the requirements are met, execute the second step; The second step: Judge whether the displacement change amount Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, Ln > Ldq, where n = 1~j, and whether all n sets of status parameters meet the conditions; if the requirements are met, output the mechanical brake status as the jacking state, which conforms to the unit operating conditions; If the requirements are not met, execute the third step; The third step: Judge whether Ln < Ldq and Ln < Llx, and whether any one set meets the conditions; where n = 1~j, and Llx is the preset falling value of the mechanical brake displacement change amount; If the requirements are met, output the mechanical brake status under the current working condition as the falling state, which does not conform to the unit operating conditions; Otherwise, wait to execute the first step; Step4: When the unit condition is the grid-connected operation state, the output status of the mechanical brake should be the falling state. Output the mechanical brake falling control instruction, perform the mechanical brake falling control, and execute the control method judgment of the falling state; The specific control method is as follows: when the collected data of digital and analog signals meet the threshold conditions for all to fall, the mechanical brake is output in the fallen state; when either the digital or analog signal meets any one of the threshold conditions for jacking up, the mechanical brake is output in the jacked-up state; The specific execution process is as follows: First step: Determine whether the action quantity Sn of the proximity switch of the mechanical brake is less than the preset falling value Slx of the proximity switch, that is, Sn < Slx, where n is the number of mechanical brakes, and whether the n sets of parameter states all meet the conditions; if the requirements are not met, then determine whether Sn > Sdq and Sn > Slx, and whether any one set meets the conditions; where n = 1 to j; j is an integer, adjusted according to the actual on-site configuration; if the requirements are met, the output state of the mechanical brake under the current working condition is the jacked-up state, which does not conform to the unit operation condition; otherwise, it means that the mechanical brake does not act in place or is in the process of falling, and continue to wait to execute the first step; if the requirements are met, execute the second step; Second step: Determine whether the displacement change quantity Ln of the mechanical brake is less than the preset falling value Llx, that is, Ln < Llx, and whether the n sets of state parameters all meet the conditions; where n = 1 to j; if the requirements are met, the output state of the mechanical brake is the fallen state, which conforms to the unit operation condition; If the requirements are not met, execute the third step; Third step: Determine whether Ln > Sdq and Ln > Llx, and whether any one set meets the conditions; where n = 1 to j; if the requirements are met, the output state of the mechanical brake under the current working condition is the jacked-up state, which does not conform to the unit operation condition; Otherwise, wait to execute the first step.

2. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 1, characterized in that: The unit working conditions are divided into the shutdown standby state and the grid-connected operation state, and the unit working condition signal is taken from the unit monitoring system database.

3. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 2 is characterized in that: When the unit working condition is the shutdown standby state, the output state of the mechanical brake corresponds to the jacked-up state, and the jacked-up control instruction of the mechanical brake is output, and the instruction is automatically issued by the shutdown process of the monitoring system. During commissioning or maintenance, the jacked-up control instruction can be manually controlled and issued by the mechanical brake cabinet; When the unit working condition is the shutdown standby state, the criterion for the jacked-up state of the mechanical brake is that the action quantity Sn of the proximity switch of the mechanical brake is greater than the preset jacked-up value Sdq of the proximity switch; at the same time, the displacement change quantity Ln of the mechanical brake is greater than the preset jacked-up value Ldq, that is, Ln > Ldq and Sn > Sdq are both satisfied.

4. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 3 is characterized in that: When the unit working condition is the grid-connected operation state, the output state of the mechanical brake corresponds to the fallen state, and the fallen control instruction of the mechanical brake is output, and the instruction is automatically issued by the startup process of the monitoring system. During commissioning or maintenance, the fallen control instruction can also be manually controlled and issued by the mechanical brake cabinet; When the unit working condition is the grid-connected operation state, the criterion for the fallen state of the mechanical brake is that the action quantity Sn of the mechanical brake is less than the preset falling value Slx of the proximity switch; at the same time, the displacement change quantity Ln of the mechanical brake is less than the preset falling value Llx, that is, Sn < Slx and Ln < Llx are both satisfied.

5. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 4 is characterized in that: The digital signal is a non-contact proximity switch signal, and its sensing distance is adjusted within the effective measurement range, which is 3 - 12 mm; the non-contact proximity switch is fixed on the mounting bracket of the base of the mechanical brake body, and the movable rod of the proximity switch is fixed at one end of the brake plate of the mechanical brake and moves synchronously with the brake plate of the mechanical brake.

6. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 5, characterized in that: The action amount Sn of the mechanical brake is the distance between the lower end face of the movable rod of the proximity switch and the top end of the contact of the proximity switch; when the action amount Sn of the mechanical brake is less than the preset falling value Slx of the proximity switch, that is, Sn < Slx indicates that the proximity switch has acted, that is, the mechanical brake is in the falling state; when the action amount Sn of the mechanical brake is greater than the preset falling value Sdq of the proximity switch, that is, Sn > Sdq indicates that the proximity switch has been restored, that is, the mechanical brake is in the restored state of the falling state.

7. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 6, characterized in that: The analog signal is the displacement amount collected by the displacement sensor, and its range should meet the maximum working stroke of the brake plate of the mechanical brake, and the maximum working stroke is 30 - 50 mm; the displacement sensor is installed on the mounting bracket of the base of the mechanical brake body, and the connecting rod of the displacement sensor is fixed at one end of the brake plate of the mechanical brake and moves synchronously with the brake plate of the mechanical brake.

8. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 7, characterized in that: The displacement change amount Ln of the mechanical brake is the distance that the connecting rod of the displacement sensor moves, that is, the distance that the brake plate of the mechanical brake moves; when the displacement change amount Ln of the mechanical brake is less than the preset falling value Llx, that is, Ln < Llx, it indicates that the displacement sensor has shrunk, that is, the mechanical brake is in the falling state; when the displacement change amount Ln of the mechanical brake is greater than the preset jacking value Ldq, that is, Ln > Ldq, it indicates that the displacement sensor has stretched, that is, the mechanical brake is in the jacking state.

9. The method for monitoring the mechanical brake state of a hydro-generator based on multiple data sources according to claim 8, characterized in that: The functions of each module in the mechanical brake state monitoring system are as follows: The signal acquisition module is used to obtain the load output and start / stop plan of the power plant unit, and obtain the operating conditions of the hydropower unit of the power plant; obtain the displacement signal of the mechanical brake and the action signal of the proximity switch; The information processing module is used to determine the应有状态 (should-be state) of the mechanical brake according to different operating conditions of the unit; and process the displacement signal of the mechanical brake and the action signal of the proximity switch according to the established control method, and output the corresponding control instructions; when the unit condition is the shutdown standby state, execute the control strategy judgment for processing the jacking state; when the unit condition is the grid-connected operation state, execute the control strategy judgment for processing the falling state; The output module is used to monitor the system and output the control instructions of the mechanical brake; when the unit condition is the shutdown standby state, the output state of the mechanical brake should be the jacking state, output the jacking control instruction of the mechanical brake, and perform the jacking control of the mechanical brake; When the unit condition is the grid-connected operation state, the output state of the mechanical brake should be the falling state, output the falling control instruction of the mechanical brake, and perform the falling control of the mechanical brake; The display module is used to display the current operating conditions of the unit and the action state and displacement change amount information of the mechanical brake.

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