Impeller tip clearance sensor calibration device and method for manufacturing an analog impeller

Abstract

The application discloses a kind of impeller machine blade tip clearance sensor calibration device and its simulation impeller manufacturing method.The sensor calibration device of the application includes base frame (2), displacement mechanism piece (5), motor (7), simulation impeller (1) and suction cup assembly;Displacement mechanism piece is installed on base frame, motor is installed on displacement mechanism piece, simulation impeller is installed on motor, and the rotation axis of simulation impeller is perpendicular to the displacement direction of displacement mechanism piece;Suction cup assembly is installed on base frame.The simulation impeller manufacturing method of the application includes: manufacturing simulation impeller of reduced scale;When obtaining the blade tip clearance signal time sequence curve of simulation impeller by blade tip clearance sensor;Grinding processing is carried out to the blade of simulation impeller;Until the blade tip clearance signal time sequence curve of simulation impeller meets the requirement.Using the sensor calibration device and its simulation impeller manufacturing method of the application, it is convenient to accurately detect signal calibration of blade tip clearance sensor on impeller machine on site.

Description

Technical Field

[0001] This invention relates to a calibration technology for an impeller testing device, and more particularly to a calibration device for an impeller tip clearance sensor and a method for manufacturing a simulated impeller. Background Technology

[0002] Turbines are important devices widely used in the aviation, shipbuilding, power, and energy industries. (See also...) Figure 1 An impeller 21 is installed inside the impeller 22. The configuration of the impeller 21 is very important for the efficient operation of the impeller 22. Therefore, the impeller 21 needs to be inspected frequently, both during the design and maintenance of the impeller.

[0003] Among the many testing items for the impeller 21, one item involves using a blade tip gap sensor 23 to detect the blade tip gap of the impeller 21, obtaining the "blade tip gap signal timing curve" for each blade in the impeller 21, and evaluating the safe distance between each blade and the casing wall of the impeller 22 based on the blade tip gap signal timing curve. Specifically, a blade tip gap sensor 23 is installed on the casing wall of the impeller 22. This blade tip gap sensor 23 has three laser ranging probes, all of which are angled towards the blade tips of the blades in the impeller 21. When the impeller 21 rotates, the three laser ranging probes measure the distance of the blade tip profiles of the blades passing by, and record the distance measurement data at each moment the blades pass by. Then, based on these distance measurement data at each moment, a curve is plotted in a two-dimensional coordinate system with time as the horizontal axis and distance measurement data as the vertical axis. This curve is the blade tip gap signal timing curve. Figure 2 As shown. It should be noted that the ranging data is represented by a voltage signal, that is, the vertical axis in the two-dimensional coordinate system is the quantization of the voltage signal. Figure 2 The labels “blade 1”, “blade 2”, and “blade 3” indicate the order in which the blades on impeller 21 pass the blade tip clearance sensor 23, with blade 1 being the first blade to pass the blade tip clearance sensor 23. Figure 2 The labels "Probe 1," "Probe 2," and "Probe 3" refer to the three laser ranging probes of the blade tip clearance sensor 23. The curves on the right are obtained by probes "Probe 1," "Probe 2," and "Probe 3," respectively. The blade tip clearance signal timing curves can be used to assess the safe distance between each blade and the casing wall of the turbine 22. This blade tip clearance sensor 23 and the method for obtaining its timing curves are fundamental technologies known to those skilled in the art.

[0004] After a period of use, the blade tip clearance sensor 23 may develop signal deviations (due to various reasons such as blade contamination and laser aging). Therefore, the blade tip clearance sensor needs to undergo signal calibration after a period of use. Currently, the signal calibration of the blade tip clearance sensor is usually performed in a laboratory. This requires personnel to first remove the blade tip clearance sensor from the impeller at the impeller site, then send it to the laboratory for signal calibration, and finally return it to the impeller for reinstallation. This entire process is time-consuming and labor-intensive, resulting in low work efficiency. Moreover, because the laboratory environment differs significantly from the on-site working conditions of the impeller, the blade tip clearance sensor calibrated in the laboratory will still have some signal deviation after being installed on the impeller, which is detrimental to accurate impeller detection.

[0005] It should be noted that the term "turbomachinery" in this article is a general term for all machines with impellers, such as jet aircraft engines with impellers, steam turbines with impellers used for thermal power generation, and so on. Summary of the Invention

[0006] One objective of this invention is to provide a calibration device for a turbine blade tip clearance sensor. This calibration device has a simple structure and small size, making it easy to carry to the field for accurate calibration of the detection signal of the blade tip clearance sensor on the turbine. A second objective of this invention is to provide a method for manufacturing a simulated turbine impeller. This method enables the production of a simulated impeller with a standard blade tip configuration for the sensor calibration device.

[0007] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution:

[0008] A calibration device for a turbine blade tip clearance sensor includes a base frame, a displacement mechanism, a motor, a simulated impeller, and a suction cup assembly. The base of the displacement mechanism is mounted on the base frame, the motor is mounted on a movable seat of the displacement mechanism, and the simulated impeller is mounted on the motor shaft, with the rotation axis of the simulated impeller perpendicular to the displacement direction of the displacement mechanism. The suction cup assembly is mounted on the base frame, and the displacement direction of the displacement mechanism is perpendicular to the suction surface of the suction cup assembly.

[0009] Furthermore, the simulated impeller has a standard blade tip simulation configuration.

[0010] Furthermore, the sensor calibration device also includes a handle, one end of which is fixedly mounted on the base frame.

[0011] Furthermore, the displacement mechanism is a knob guide rail displacement mechanism.

[0012] Furthermore, the suction cup assembly includes a suction cup bracket, two suction cups, and two suction cup fastening nuts. The suction cup bracket is mounted on a base frame, and bolt mounting holes are provided at both the upper and lower ends of the suction cup bracket. A screw is provided on the back of each suction cup. The screws of the two suction cups pass through the bolt mounting holes at the upper and lower ends of the suction cup bracket and are threadedly connected to and fastened to the two suction cup fastening nuts respectively. The displacement direction of the displacement mechanism is perpendicular to the suction surface of the suction cup.

[0013] Furthermore, the base frame is provided with numerous mounting holes.

[0014] A method for manufacturing a simulated impeller for a turbomachinery, wherein the simulated impeller is used to be installed in the aforementioned impeller tip clearance sensor calibration device; the method for manufacturing the simulated impeller includes:

[0015] S1, Based on the configuration design parameters of the impeller, a scaled-down simulated impeller is manufactured;

[0016] S2, install the simulated impeller on the motor shaft of the sensor calibration device, and fix the sensor calibration device to the blade tip gap sensor position on the impeller casing wall by suction cup assembly, so that the blade tip of the simulated impeller of the sensor calibration device is facing the blade tip gap sensor.

[0017] S3, start the motor of the sensor calibration device to make the simulated impeller rotate, and then use the blade tip gap sensor to detect the rotating simulated impeller and obtain the blade tip gap signal timing curve of the simulated impeller through the blade tip gap sensor;

[0018] S4. Compare the timing curve of the blade tip gap signal of the simulated impeller with the timing curve of the standard blade tip gap signal. If the comparison shows that there is a difference between the two, the simulated impeller is removed from the sensor calibration device and the blades of the simulated impeller are ground.

[0019] S5. Repeat S2 to S4 until the timing curve of the simulated impeller tip clearance signal matches the timing curve of the standard tip clearance signal.

[0020] Furthermore, the grinding process includes: grinding the surface of the simulated impeller blade to reduce the blade thickness; coating the surface of the simulated impeller blade with a coating having a certain reflectivity to simulate the light reflectivity of a real blade; grinding the blade tip profile of the simulated impeller blade to change the curvature of the blade tip profile; and grinding the side profile of the simulated impeller blade to change the curvature of the side profile.

[0021] The sensor calibration device of the present invention is equipped with a simulated impeller driven by a motor. The simulated impeller has a standard blade tip simulation configuration, so it can provide the blade tip gap sensor with a blade tip profile movement trajectory that perfectly conforms to the standard blade tip gap signal timing curve. This provides an accurate calibration reference for the detection signal calibration of the blade tip gap sensor. Based on this, the blade tip gap sensor can complete accurate detection signal calibration.

[0022] Compared with the prior art, the sensor calibration device and its simulated impeller manufacturing method of the present invention have the following advantages: The sensor calibration device of the present invention enables the tip gap sensor to complete accurate detection signal calibration. Furthermore, the sensor calibration device has the advantages of simple structure and small size, making it easy for operators to carry. Operators can carry the sensor calibration device to the impeller site and then directly calibrate the detection signal of the tip gap sensor installed on the impeller on-site. Compared with the detection signal calibration in the laboratory, it eliminates the cumbersome process of disassembling and moving the tip gap sensor, thereby improving work efficiency. It also avoids the situation where "due to the significant difference between the laboratory environment and the working environment of the impeller site, the tip gap sensor calibrated in the laboratory still has a certain signal deviation after being installed on the impeller". The tip gap sensor that has been calibrated by detection signal obtains more accurate data for impeller detection. The simulated impeller manufactured using the simulated impeller manufacturing method of the present invention has a standard blade tip simulation configuration, and the sensor calibration device installed on the simulated impeller can provide an accurate calibration reference for the detection signal calibration of the blade tip gap sensor. Attached Figure Description

[0023] Figure 1 A schematic diagram of installing a blade tip clearance sensor on the casing wall of a turbomachinery to detect the impeller;

[0024] Figure 2 A timing curve of the tip gap signal obtained by the tip gap sensor from the impeller;

[0025] Figure 3 This is a schematic diagram of the turbine blade tip clearance sensor calibration device of the present invention;

[0026] Figure 4 This is an exploded view of the sensor calibration device of the present invention;

[0027] Figure 5 This is a schematic diagram of the displacement mechanism in the sensor calibration device of the present invention;

[0028] Figure 6 This is a schematic diagram of calibrating the detection signal of the blade tip gap sensor using the sensor calibration device of the present invention.

[0029] In the diagram: 1-Simulated impeller, 2-Base frame, 3-Handle, 4-Handle connecting block, 5-Displacement mechanism, 51-Base, 52-Adjustment knob, 53-Moving seat, 54-Locking screw, 55-Guide rail, 6-Motor bracket, 7-Motor, 8-Suction cup bracket, 9-Suction cup, 10-Suction cup fastening nut, 11-Shaft sleeve, 21-Impeller, 22-Impeller mechanism, 23-Impeller tip gap sensor. Implementation

[0030] First, some concepts involved in this article are explained as follows:

[0031] The “designed distance from blade tip to casing wall” mentioned in this article refers to the pre-designed distance from the blade tip of the actual impeller to the casing wall of the impeller.

[0032] The "tipping gap signal timing curve of the impeller" mentioned in this article refers to the timing curve of the tip gap signal obtained by using a tip gap sensor to detect the tip gap of the impeller.

[0033] The "standard blade tip clearance signal timing curve" mentioned in this article refers to the blade tip clearance signal timing curve obtained by using a blade tip clearance sensor to detect the blade tip clearance of a real impeller that meets the design standards.

[0034] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0035] See Figures 3 to 6 This embodiment provides a calibration device for a turbine blade tip clearance sensor. This sensor calibration device has the advantages of simple structure and small size, and is easy to carry to the field to accurately calibrate the detection signal of the blade tip clearance sensor on the turbine.

[0036] See Figure 3 and Figure 4 The sensor calibration device in this embodiment includes a base frame 2, a handle 3, a handle connecting block 4, a displacement mechanism 5, a motor bracket 6, a motor 7, a simulated impeller 1, a bushing 11, and a suction cup assembly.

[0037] The base frame 2 is generally U-shaped, with one side of the U being the first side and the other side being the second side. Furthermore, numerous mounting holes are provided on the base frame 2, covering the entire base frame 2. These mounting holes allow other components to be installed at any position on the base frame 2. The handle connecting block 4, the displacement mechanism 5, and the suction cup assembly, described later, are all mounted to these mounting holes using bolts.

[0038] The handle connecting block 4 is bolted to the first side of the base frame 2, and one end of the handle 3 is bolted to the handle connecting block 4. That is, one end of the handle 3 is fixedly mounted to the first side of the base frame 2 via the handle connecting block 4. The handle 3 on the sensor calibration device facilitates the operator's gripping and manipulation of the sensor calibration device.

[0039] See Figure 5 The displacement mechanism 5 is a knob-guide rail displacement mechanism. Specifically, the displacement mechanism 5 includes a base 51 and a movable seat 53. A guide rail 55 is provided on the base 51, and a guide rail groove is formed below the movable seat 53. The guide rail groove of the movable seat 53 cooperates with the guide rail 55 of the base 51, so the movable seat 53 can make linear displacement relative to the base 51 along the guide rail 55. The direction of linear displacement of the movable seat 53 relative to the base 51 is the displacement direction of the displacement mechanism 5. An adjustment knob 52 is provided on the side of the movable seat 53. One end of the adjustment knob 52 is connected to the displacement transmission mechanism inside the movable seat 53. Rotating the adjustment knob 52 can control the displacement of the movable seat 53 on the base 51. The locking screw 54 is used to lock the movable seat 53. When the locking screw 54 is tightened, the movable seat 53 cannot move relative to the base 51. In addition, a length scale is provided on the base 51 to facilitate observation of the displacement position of the movable seat 53 relative to the base 51. This knob guide rail displacement mechanism is a prior art mechanism, and its specific structure and function are common knowledge to those skilled in the art.

[0040] See Figure 3 and Figure 4 The base of the displacement mechanism 5 is bolted to the U-shaped recess in the middle of the base frame 2. The motor bracket 6 is bolted to the movable seat of the displacement mechanism 5. The motor 7 is mounted on the motor bracket 6, that is, the motor 7 is mounted on the movable seat of the displacement mechanism 5 via the motor bracket 6. The simulated impeller 1 is mounted on the rotating shaft of the motor 7 via the bushing 11. The simulated impeller 1 is detachable and replaceable. The rotation axis of the simulated impeller 1, or in other words, the rotation axis of the motor 7, must be perpendicular to the displacement direction of the displacement mechanism 5 (the direction of the guide rail 55).

[0041] The motor 7 is powered by a lithium battery (not shown in the figure).

[0042] The simulated impeller 1 has a standard blade tip simulation configuration. Here, "has a standard blade tip simulation configuration" means that the timing curve of the blade tip gap signal obtained by the blade tip gap sensor from the simulated impeller 1 is consistent with the timing curve of the standard blade tip gap signal.

[0043] The suction cup assembly is mounted on the second side of the base frame 2. Specifically, the suction cup assembly includes a suction cup bracket 8, two suction cups 9, and two suction cup fastening nuts 10. The suction cup bracket 8 is mounted on the second side of the base frame 2 by bolts. Bolt mounting holes are provided at both the upper and lower ends of the suction cup bracket 8. The two suction cups 9 are respectively mounted at the bolt mounting holes at the upper and lower ends of the suction cup bracket 8. Specifically, a screw is fixedly provided on the back of the suction cup 9. The screw of the suction cup 9 passes through the bolt mounting hole and is threadedly connected to the suction cup fastening nut 10 and tightened for fixation.

[0044] The displacement direction of the displacement mechanism 5 is perpendicular to the adsorption surface of the suction cup 9 of the suction cup assembly. In this way, the simulated impeller 1 and the motor 7 can be driven away from or close to the impeller casing wall adsorbed by the suction cup assembly.

[0045] See Figure 6 When calibrating the blade tip gap sensor 23 on the casing wall of the impeller 22 using the sensor calibration device of this embodiment, the suction cup assembly (suction cup 9) of the sensor calibration device is adsorbed and fixed at the position of the blade tip gap sensor 23 on the casing wall of the impeller 22, so that the blade tip of the simulated impeller 1 is facing the blade tip gap sensor 23. Then, the displacement mechanism 5 is adjusted so that the distance between the blade tip of the simulated impeller 1 and the blade tip gap sensor 23 conforms to the "design distance from blade tip to casing wall". Then, the motor 7 is started to drive the simulated impeller 1 to rotate. When the blade tip of the simulated impeller 1 blade sweeps past the blade tip gap sensor 23, it provides the blade tip gap sensor 23 with a blade tip profile movement trajectory that conforms to the "standard blade tip gap signal timing curve". The blade tip gap sensor 23 can then be calibrated according to the blade tip profile movement trajectory.

[0046] The sensor calibration device in this embodiment includes a simulated impeller 1 driven to rotate by a motor 7. The simulated impeller 1 has a standard blade tip simulation configuration, which can provide the blade tip gap sensor with a blade tip profile movement trajectory that perfectly conforms to the "standard blade tip gap signal timing curve". This provides an accurate calibration reference for the detection signal calibration of the blade tip gap sensor. Based on this, the blade tip gap sensor can complete accurate detection signal calibration. Furthermore, the sensor calibration device of this embodiment has the advantages of simple structure and small size, making it easy for operators to carry. Operators can take the sensor calibration device to the impeller site and then directly calibrate the detection signal of the blade tip clearance sensor installed on the impeller on-site. Compared with the detection signal calibration in the laboratory, it eliminates the cumbersome process of disassembling and moving the blade tip clearance sensor, thereby improving work efficiency. It also avoids the situation where "due to the significant difference between the laboratory environment and the working environment of the impeller site, the blade tip clearance sensor calibrated in the laboratory will still have a certain signal deviation after being installed on the impeller". The blade tip clearance sensor that has been calibrated by detection signal will obtain more accurate data for impeller detection.

[0047] Because the configurations of impellers differ between different models of impellers, a corresponding simulated impeller can be fabricated and prepared for each model of impeller in the production operation site. When it is necessary to calibrate the detection signal of the tip clearance sensor on a certain model of impeller, the simulated impeller corresponding to that model of impeller is installed on the motor of the sensor calibration device, and then the sensor calibration device is used to calibrate the detection signal of the tip clearance sensor.

[0048] This embodiment also provides a method for manufacturing a simulated impeller for a turbomachinery. The simulated impeller mentioned here refers to the simulated impeller 1 installed in the aforementioned sensor calibration device.

[0049] The simulated impeller manufacturing method of this embodiment includes S1 to S5.

[0050] S1. Based on the configuration design parameters of a certain type of impeller, manufacture a simulated impeller with a scaled-down ratio for that type of impeller.

[0051] S2, the simulated impeller is installed on the motor 7 shaft of the sensor calibration device, and the sensor calibration device is attached to the blade tip gap sensor position on the impeller casing wall by suction cup assembly, so that the blade tip of the simulated impeller 1 of the sensor calibration device is facing the blade tip gap sensor. Then, the displacement mechanism 5 is adjusted so that the distance between the blade tip of the simulated impeller 1 and the blade tip gap sensor conforms to the design distance from the blade tip to the casing wall.

[0052] S3, start the motor 7 of the sensor calibration device to make the simulated impeller 1 rotate, and then use the blade tip gap sensor to detect the rotating simulated impeller and obtain the timing curve of the blade tip gap signal of the simulated impeller through the blade tip gap sensor.

[0053] S4. Compare the timing curve of the blade tip gap signal of the simulated impeller with the timing curve of the standard blade tip gap signal. If the comparison shows that there is a difference between the two curves, the simulated impeller is removed from the sensor calibration device. Then, based on the difference found in the comparison, the blades of the simulated impeller are ground to make the timing curve of the blade tip gap signal of the simulated impeller consistent with the timing curve of the standard blade tip gap signal.

[0054] The grinding process includes:

[0055] The surface of the simulated impeller blades was polished to reduce the blade thickness;

[0056] A coating with a certain reflectivity is applied to the surface of the simulated impeller blades to simulate the light reflectivity of real blades, so that the simulated impeller blades can correctly reflect the laser ranging signal.

[0057] The blade tip profile of the simulated impeller is ground to change the curvature of the blade tip profile;

[0058] The side profile of the simulated impeller blades is ground to change the curvature of the blade side profile.

[0059] S5. Repeat S2 to S4 until the timing curve of the simulated impeller tip clearance signal matches the timing curve of the standard tip clearance signal.

[0060] The simulated impeller manufactured using the simulated impeller manufacturing method of this embodiment has a blade tip gap signal timing curve that is consistent with the standard blade tip gap signal timing curve. That is, the simulated impeller has a standard blade tip simulation configuration. The sensor calibration device installed on the simulated impeller can provide an accurate calibration reference for the detection signal calibration of the blade tip gap sensor. Based on this, the blade tip gap sensor can complete accurate detection signal calibration.

[0061] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a simulated impeller for a turbomachinery, wherein the simulated impeller is used to be installed in a turbomachinery blade tip clearance sensor calibration device. The impeller blade tip gap sensor calibration device includes a base frame (2), a displacement mechanism (5), a motor (7), a simulated impeller (1), and a suction cup assembly; The base of the displacement mechanism (5) is mounted on the base frame (2), the motor (7) is mounted on the movable seat of the displacement mechanism (5), the simulated impeller (1) is mounted on the rotating shaft of the motor (7), and the rotation axis of the simulated impeller (1) is perpendicular to the displacement direction of the displacement mechanism (5). The suction cup assembly is mounted on the base frame (2), and the displacement direction of the displacement mechanism (5) is perpendicular to the adsorption surface of the suction cup assembly. characterized in that The method for manufacturing the simulated impeller includes: S1, Based on the configuration design parameters of the impeller, a scaled-down simulated impeller is manufactured; S2, install the simulated impeller on the motor (7) shaft of the sensor calibration device, and fix the sensor calibration device to the blade tip gap sensor position on the impeller casing wall by suction cup assembly, so that the blade tip of the simulated impeller (1) of the sensor calibration device is facing the blade tip gap sensor. S3, start the motor (7) of the sensor calibration device to make the simulated impeller (1) rotate, and then use the blade tip gap sensor to detect the rotating simulated impeller and obtain the blade tip gap signal timing curve of the simulated impeller through the blade tip gap sensor; S4. Compare the timing curve of the blade tip gap signal of the simulated impeller with the timing curve of the standard blade tip gap signal. If the comparison shows that there is a difference between the two, the simulated impeller is removed from the sensor calibration device and the blades of the simulated impeller are ground. S5. Repeat S2 to S4 until the timing curve of the simulated impeller tip clearance signal matches the timing curve of the standard tip clearance signal.

2. The method of claim 1, wherein: The grinding process includes: The surface of the simulated impeller blades was polished to reduce the blade thickness; A coating with a certain reflectivity is applied to the surface of the simulated impeller blades to simulate the light reflectivity of real blades; The blade tip profile of the simulated impeller is ground to change the curvature of the blade tip profile; The side profile of the simulated impeller blades is ground to change the curvature of the blade side profile.

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