A method for calculating the levelness of a mirror plate during turning

Abstract

A method for calculating the levelness of a mirror plate during the turning process involves first obtaining the azimuth and levelness of the mirror plate through vector decomposition, then adjusting each support bolt to level the mirror plate, then obtaining the axis adjustment scheme after the mirror plate is leveled, and finally obtaining the rotation center adjustment scheme after obtaining the axis adjustment scheme.

Description

Technical Field

[0001] This invention relates to the field of hydropower unit facilities and equipment technology, specifically to a system and method for obtaining shaft system state characteristic parameters of hydropower generator sets. This invention is a divisional application of the invention patent entitled "A System and Method for Obtaining Shaft System State Characteristic Parameters of Hydropower Generator Sets", application number 202111146420.7. Background Technology

[0002] In traditional methods of obtaining shaft system adjustment schemes for hydro-generator units, the current state of the main shaft system is calculated through turning gear data. Operators analyze the calculated results of the main shaft system state and, based on human experience, initially determine a shaft system adjustment scheme. This scheme is then substituted into the calculation formula to test the result of adjusting the main shaft system state according to this scheme. If the result is acceptable, the shaft system is adjusted according to this scheme. If the result is unacceptable, a different adjustment scheme is used for testing until an acceptable result is obtained. Generally speaking, for traditional turning gear shaft system adjustment methods for hydro-generator units, not only is the turning gear cycle long, the workload of manual measurement and calculation large, but the number of fixed-point turning gear measurement points is also small, resulting in low calculation accuracy. Furthermore, the biggest drawback is that the shaft system adjustment scheme is entirely dependent on human experience, requiring multiple trial calculations to determine an acceptable, but not necessarily optimal, adjustment scheme.

[0003] In view of this, the applicant proposes a system for obtaining the characteristic parameters of the shaft system of a hydro-generator unit and a method for calculating the levelness of the mirror plate during the turning process. Summary of the Invention

[0004] The purpose of this invention is to realize the automatic data acquisition and automatic calculation and analysis during the adjustment process of the shaft system of a hydro-generator unit, and to provide a reliable basis for the final automatic shaft system adjustment scheme. It provides a system and method for obtaining the characteristic parameters of the shaft system of a hydro-generator unit, and a method for calculating the levelness of the mirror plate during the turning process.

[0005] A system for acquiring shaft system state characteristic parameters of a hydro-generator unit includes a phase acquisition device, a mirror plate level measurement device, and a swing sensor.

[0006] The phase acquisition device is located at the spindle and is used to acquire the spindle phase during rotary rotation.

[0007] The mirror plate level measuring device is set on the horizontal surface of the rotating component and is used to automatically and continuously measure the levelness of the unit's mirror plate during turning.

[0008] The runout sensor is used to measure the gap between the sensor and the spindle; the sensor in-situ calibration device is used to perform on-site online calibration of the sensitivity coefficient of the eddy current sensor.

[0009] The aforementioned phase acquisition device includes a support column and a base connected to the bottom of the support column. A rotating arm is sleeved on the support column, and the rotating arm includes an upper rotating arm and a lower rotating arm sleeved on the support column. A limiting block is provided between the upper rotating arm and the lower rotating arm. The limiting block is sleeved on the support column and is connected to the support column by a set screw. One end of the connecting plate is connected to the rotating arm by a fastening screw, and the relative position can be adjusted by a straight sliding groove provided on the connecting plate. The other end of the connecting plate is connected to a fixing plate by a fastening screw. The rotary encoder is fixed by a fastening screw on the fixing plate.

[0010] A hook is provided on the back of the fastening screw, which is connected to the limit block by a spring to apply preload to the rotation of the swing arm; an arc-shaped groove is provided at the end where the fixed plate connects to the connecting plate, which allows the fixed plate to be finely adjusted in the up-down, back-and-forth and circumferential directions.

[0011] The aforementioned mirror plate level measuring device includes a level measuring sensor and a data acquisition module connected to the level measuring sensor;

[0012] When calculating the levelness of the mirror plate using a mirror plate level measuring device during the turning process, the following method is adopted:

[0013] At any orientation of the mirror plate, the tilt angle data collected by the horizontal measurement sensor is decomposed into X and Y vectors. For example, at a mirror plate angle αi, the collected tilt angle data β αi Decomposed into X-direction vector β αiX and the Y-direction vector β αiY for:

[0014] β αiX =β αi cosαi;αi∈[0,360)

[0015] β αiY =β αi sinαi;αi∈[0,360)

[0016] The tilt angle X and direction vector β of the plane measured by the horizontal sensor during one revolution of the unit X and the Y vector β X The calculation method is as follows:

[0017]

[0018]

[0019] The calculation methods for inclination angle β and azimuth angle θ are as follows:

[0020]

[0021]

[0022] Then the horizontal azimuth angle of the mirror plate is θ, and the horizontality H (mm / m) is:

[0023] H = tgβ × 1000; (mm / m).

[0024] The aforementioned swing sensor is an eddy current sensor;

[0025] The sensitivity coefficient of the eddy current sensor is calibrated using an in-situ calibration device.

[0026] The sensor in-situ calibration device includes a base, on which a high-precision translation platform is provided. A vertically arranged column is connected at its bottom end to the upper end face of the high-precision translation platform. An eddy current sensor is provided at the upper end of the column and perpendicular to the column.

[0027] The aforementioned column is parallel to the main shaft, and the eddy current sensor has a strip-shaped structure with its detection end close to the main shaft.

[0028] A circular hole is provided through the upper end of the column. The eddy current sensor is connected to the circular hole laterally and fixed to the upper end of the column by a fixing nut.

[0029] The high-precision translation platform can move the column in the X / Y direction.

[0030] The high-precision translation platform includes an X-axis adjustment module, a Y-axis adjustment module, and adjustment knobs. The X-axis adjustment module can generate precise X-axis displacement through the X-axis coarse adjustment knob and the X-axis fine adjustment knob, and the Y-axis adjustment module can generate precise Y-axis displacement through the Y-axis coarse adjustment knob and the Y-axis coarse adjustment knob.

[0031] When calibrating the sensitivity coefficient of an eddy current sensor using an in-situ calibration device, the following steps are taken:

[0032] 1) Fix the in-situ calibration device near the measurement location of the sensor; then fix the eddy current sensor on the in-situ calibration device, connect the output signal of the calibrated eddy current sensor to the acquisition device of this layer, and provide power to the sensor.

[0033] 2) After the above preparations are completed, the distance between the eddy current sensor and the spindle is adjusted by a high-precision translation platform. The voltage / current signal output by the calibrated sensor is automatically recorded by the signal processing computer. In addition, the high-precision scale data on the in-situ calibration device is read manually to calculate the gap adjustment value between the eddy current sensor and the spindle, and the data is synchronously input into the computer.

[0034] 3) After obtaining signals and data from multiple displacement points through the above steps, the signal processing computer uses the least squares method to calculate the sensitivity coefficient of the calibrated sensor.

[0035] 4) Using the obtained sensitivity coefficient to be calibrated, adjust the distance between the spindle surface and the sensor. At the same time, record the displacement output measured by the eddy current sensor and the actual displacement measured manually, and compare the error between the two point by point to form an error analysis report. If the error between the two is within the allowable range, the online calibration is completed, and the sensitivity coefficient to be calibrated is the sensitivity coefficient of the eddy current sensor used in this system.

[0036] A spindle phase acquisition method includes the following steps when acquiring the spindle phase:

[0037] 1) The rotary encoder adopts the contact principle, and the roller of the rotary encoder is in direct contact with the main shaft of the unit;

[0038] 2) When the spindle rotates, it drives the rollers of the rotary encoder to rotate;

[0039] 3) A rotation pulse sensor mounted on the roller sends out a series of pulses, each pulse representing a certain distance value;

[0040] 4) The pulse signal from the rotary encoder is sent to the wireless acquisition unit via a signal cable, converted into digital quantities of 0s and 1s, and then transmitted wirelessly to the data processing unit via Wi-Fi. The data processing unit counts based on the 0s and 1s, thereby calculating the rotational phase and linear velocity of the spindle.

[0041] When the rotary encoder's rollers rotate, the rotation pulse sensor on the rollers sends out a series of pulses. Each pulse represents a specified displacement value produced by the rollers. Let the spindle diameter be D (unit: mm), and the pulse count in time t be n. Then, the formula for calculating the spindle rotation angle α at that moment is:

[0042]

[0043] The linear velocity V1 of the roller rotation is:

[0044] The linear velocity V2 of the spindle rotation is:

[0045] A method for calculating the levelness of the mirror plate during the turning process, which employs the following method:

[0046] At any position of the mirror plate, the tilt angle data collected by the horizontal measuring sensor 2-1 is decomposed into X and Y vectors. For example, at the mirror plate angle αi, the collected tilt angle data β αi Decomposed into X-direction vector β αiX and the Y-direction vector β αiY for:

[0047] β αiX =βαi cosαi;αi∈[0,360)

[0048] β αiY =β αi sinαi;αi∈[0,360)

[0049] The tilt angle X and direction vector β of the plane measured by the horizontal sensor during one revolution of the unit X and the Y vector β X The calculation method is as follows:

[0050]

[0051]

[0052] The calculation methods for inclination angle β and azimuth angle θ are as follows:

[0053]

[0054]

[0055] Then the horizontal azimuth angle of the mirror plate is θ, and the horizontality H (mm / m) is:

[0056] H = tgβ × 1000; (mm / m).

[0057] Compared with the prior art, the present invention has the following technical effects:

[0058] 1) This invention fills the gap in the technology of continuous turning gear shaft adjustment for vertical hydro turbine generator sets. For the first time, it adopts electrical measurement method to automatically collect data, wireless communication, automatic calculation and analysis, and automatically provide shaft adjustment scheme. It solves the problems of low automation and large errors in manual measurement / calculation in traditional methods. It can significantly improve the working efficiency and adjustment accuracy of the unit shaft adjustment, shorten the maintenance period, and save manpower and material resources.

[0059] 2) This invention uses a contact rotary encoder to achieve high-precision continuous measurement of the spindle phase under any turning mode, solving the problem that traditional technologies such as key phase measurement, photoelectric measurement, and gear plate measurement cannot perform continuous measurement of the spindle phase;

[0060] 3) Compared with the traditional method of measuring the level of the mirror plate, which usually uses a coincidence level instrument, has few measurement points and requires manual reading, resulting in low accuracy, reading errors and inaccurate stop points, the mirror plate level measurement technology used in this invention can realize continuous wireless acquisition of the mirror plate level.

[0061] 4) The in-situ calibration technology of the sensor used in this invention can effectively calibrate the sensitivity coefficient of the eddy current sensor on site, and effectively eliminate the influence of the spindle material and curvature on the measurement results. Attached Figure Description

[0062] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0063] Figure 1 This is a schematic diagram of the overall structure of the system in this invention;

[0064] Figure 2 for Figure 1 Schematic diagram of the mid-phase acquisition device;

[0065] Figure 3 This is a front view of the phase acquisition device;

[0066] Figure 4 This is a rear view of the phase acquisition device;

[0067] Figure 5 for Figure 1 A schematic diagram of the in-situ calibration device for the sensor. Detailed Implementation

[0068] like Figure 1 As shown, a system for obtaining the shaft system state characteristic parameters of a hydro-generator unit is described.

[0069] It includes a phase acquisition device 1, a mirror plate level measuring device 2, and a swing sensor 4;

[0070] Phase acquisition device 1 is installed at the main spindle 5 and is used to acquire the phase of the main spindle during rotation.

[0071] The mirror plate level measuring device 2 is set on the horizontal surface of the rotating component and is used to automatically and continuously measure the levelness of the unit's mirror plate during turning.

[0072] The swing sensor 4 uses an eddy current sensor;

[0073] The sway sensor 4 is used to measure the gap value between itself and the spindle 5; the sensor in-situ calibration device 3 is used to perform on-site online calibration of the sensitivity coefficient of the eddy current sensor.

[0074] About eddy current sensors:

[0075] 1) The probe is mounted near the spindle being measured using a magnetic support;

[0076] 2) The probe must be installed directly opposite the center of the spindle;

[0077] 3) The probe must be aligned with the effective measurement surface; the effective measurement surface refers to a surface that is free of scratches, holes, protrusions, etc., and has a smooth surface without any coating.

[0078] 4) The gap between the probe and the spindle must be adjusted properly;

[0079] 5) Ensure correct wiring; connect directly to the wireless acquisition unit.

[0080] The mirror plate level measuring device 2 includes a mirror plate level sensor. Regarding the mirror plate level sensor:

[0081] 1) The horizontal measurement sensor and the wireless acquisition and power supply device for the sensor are placed horizontally on the thrust head;

[0082] 2) Sensors and wireless data acquisition and power supply devices ensure unobstructed operation during unit rotation;

[0083] 3) The sensor uses wireless transmission to transmit data to the signal processor via a repeater.

[0084] like Figure 2 , Figure 3 , Figure 4 As shown, to achieve more time-saving, labor-saving, and accurate acquisition of the spindle phase during the rotation process, a phase acquisition device is provided. It includes a support column 1-2 and a base 1-1 connected to the bottom of the support column 1-2. A rotating arm 1-3 is sleeved on the support column 1-2, and includes an upper rotating arm and a lower rotating arm sleeved on the support column 1-2. A limiting block 1-7 is provided between the upper and lower rotating arms, and the limiting block 1-7 is sleeved on the support column 1-2. The limiting block 1-7 is connected to the support column 1-2 via a set screw 1-8. One end of a connecting plate 1-4 is connected to the rotating arm 1-3 via a fastening screw 1-9, and its relative position can be adjusted via a straight sliding groove provided on the connecting plate 1-4. The other end of the connecting plate 1-4 is connected to a fixing plate 1-5 via a fastening screw 1-10. A rotary encoder 1-12 is fixed via a fastening screw 1-11 on the fixing plate 1-5. The phase acquisition device is used to install and fix the spindle phase sensor.

[0085] Regarding the spindle phase sensor:

[0086] 1) The probe is mounted near the spindle being measured using a magnetic support;

[0087] 2) The hard polyurethane rubber rollers for the sensor need to be tangent to the main shaft;

[0088] 3) Connect directly to the data collector, ensuring correct wiring.

[0089] Furthermore, a hook is provided on the back of the fastening screw 1-9, which is connected to the limit block 1-7 via spring 1-6. This hook is used to apply preload to the rotation of the rotating arm 1-3. The rotary encoder 1-12 is pressed tightly against the cylindrical measuring surface of the main shaft 5 of the unit by the preload generated by spring 1-6, which greatly increases the damping between the encoder roller and the main shaft 5 and effectively prevents slippage.

[0090] To facilitate fine-tuning of the bracket, an arc-shaped groove is provided at the end where the fixing plate 1-5 connects to the connecting plate 1-4, allowing the fixing plate 1-5 to be finely adjusted in the vertical, horizontal, and circumferential directions.

[0091] In the data transmission method, the acquisition signals of rotary encoders 1-12 are sent to the wireless acquisition unit through the signal cable, and then transmitted to the data processing unit wirelessly / wiredly.

[0092] Rotary encoders 1-12 are installed on the main shaft 5 and are used to continuously acquire the phase of the main shaft during rotation.

[0093] The contact-type rotary encoder sensor is in direct contact with the unit's main shaft. When the main shaft rotates, it contacts the rotary speed sensor, and friction drives the sensor's roller to rotate. A rotational pulse sensor mounted on the roller sends out a series of pulses. Each pulse represents a certain distance value, thus measuring the linear velocity V. Assuming D is the roller diameter in mm, and the roller outputs πD pulses per revolution, then one pulse represents a distance of 1 mm. Let the pulse count in time t be n, then the linear velocity V is: In this system, measuring the rotational linear velocity of the spindle surface is not the goal; the real objective is to measure the phase. Correspondingly, the accumulated pulse count corresponds to the phase of the unit's rotation.

[0094] To facilitate the installation of the base, the base 1-1 is a magnetic base that can be attracted to the metal surface.

[0095] A hard polyurethane rubber layer is provided on the roller surface of rotary encoders 1-12.

[0096] When using this invention, the following steps are adopted:

[0097] 1) The rotary encoder 1-12 adopts the contact principle, and the roller of the rotary encoder 1-12 is in direct contact with the main shaft 5 of the unit;

[0098] 2) When the main shaft 5 rotates, the main shaft 5 drives the rollers of the rotary encoders 1-12 to rotate;

[0099] 3) A rotation pulse sensor mounted on the roller sends out a series of pulses, each pulse representing a certain distance value;

[0100] 4) The pulse signals from rotary encoders 1-12 are sent to the wireless acquisition unit via signal cables, converted into digital quantities of 0 and 1, and then transmitted wirelessly to the data processing unit via WIFI. The data processing unit counts based on the 0 and 1, thereby calculating the rotational phase and linear velocity of the spindle.

[0101] When the rollers of rotary encoders 1-12 rotate, the rotation pulse sensors on the rollers send out a series of pulses. Each pulse represents a displacement of 1 mm for the roller. Let the spindle diameter be D (unit: mm), and the pulse count in time t be n. Then, the formula for calculating the spindle rotation angle α at that moment is:

[0102]

[0103] The linear velocity V1 of the roller rotation is:

[0104] The linear velocity V2 of the spindle rotation is:

[0105] To achieve accurate measurements, when using the fixed-point rotation method, the number of rotations should be 1 to 2. Set the spindle phase at the starting point of rotation to 0°, and the rotary encoder will automatically collect data and perform phase calculations during the rotation process.

[0106] When using continuous rotating shaft rotation, the number of rotations is unlimited. However, a key phase signal is required to eliminate the accumulated error in phase measurement. When a key phase signal appears after each rotation of the main shaft, the accumulated pulses collected by rotary encoders 1-12 are set to zero to eliminate the phase measurement error of the previous cycle. Subsequent pulses are then re-accumulated to obtain the accurate phase of the unit's main shaft at any given time.

[0107] Furthermore, a key phase block can be attached to the main shaft to simultaneously acquire key phase signals and pulse data from a contact-type rotary speed sensor. At the same time, the pulses output by the phase sensor are accumulated to obtain the real-time relative angle. If a key phase signal is acquired in the key phase signal, the pulse accumulation is set to zero. Subsequent pulse accumulation will be based on this foundation through integration and summation. Based on the accumulated pulse count, the diameter of the main shaft, and the pulse equivalent of the sensor, the accurate phase of the unit's main shaft at any given time (relative to the initial phase) can be obtained.

[0108] The mirror plate level measuring device 2 includes a level measuring sensor and a data acquisition module connected to the level measuring sensor;

[0109] The following method is used to calculate the levelness of the mirror plate during the rotation process:

[0110] At any position of the mirror plate, the tilt angle data collected by the horizontal measuring sensor 2-1 is decomposed into X and Y vectors. For example, at the mirror plate angle αi, the collected tilt angle data β αi Decomposed into X-direction vector β αiX and the Y-direction vector β αiY for:

[0111] β αiX =β αicosαi;αi∈[0,360)

[0112] β αiY =β αi sinαi;αi∈[0,360)

[0113] The tilt angle X and direction vector β of the plane measured by the horizontal sensor during one revolution of the unit X and the Y vector β X The calculation method is as follows:

[0114]

[0115]

[0116] The calculation methods for inclination angle β and azimuth angle θ are as follows:

[0117]

[0118]

[0119] Then the horizontal azimuth angle of the mirror plate is θ, and the horizontality H (mm / m) is:

[0120] H = tgβ × 1000; (mm / m).

[0121] The mirror plate level measuring device 2 is wirelessly connected to the wireless acquisition unit deployed on the lower guide bearing (or thrust bearing). Each layer of wireless acquisition unit converts the acquired sensor signals into digital signals, which are then amplified by a signal repeater and wirelessly transmitted to the data processing unit. The data processing unit acquires the acquired data via Ethernet, processes the data, and uses software algorithms to obtain characteristic parameters reflecting the unit's shaft system status. Finally, it generates a shaft system adjustment scheme using a shaft system adjustment calculation model.

[0122] The horizontal measurement sensor and data acquisition module are connected via RS232 wired connection. A battery module is also included, which powers both the horizontal measurement sensor and the data acquisition module. The data acquisition module communicates with the wireless data acquisition unit via Wi-Fi. The wireless data acquisition unit communicates with the data processing unit via Wi-Fi.

[0123] Since the geometry, dimensions, and current frequency of an eddy current sensor are fixed, its sensitivity depends not only on the distance between the probe and the surface of the metal being measured, but also on the magnetic permeability and conductivity of the metal. Therefore, the sensitivity of the same eddy current sensor will differ when measuring the displacement of metals with different magnetic permeabilities and conductivity. Figure 5As shown, in order to calibrate the sensitivity of the eddy current sensor when measuring spindles of different materials, the present invention provides a sensor in-situ calibration device;

[0124] The in-situ calibration device for the swing angle sensor of the hydropower unit includes a base 3-1, a high-precision translation platform 3-2 on the base 3-1, a vertically arranged column 3-4 connected at its bottom end to the upper end face of the high-precision translation platform 3-2, and an eddy current sensor 3-6 arranged at the upper end of the column 3-4 and perpendicular to the column 3-4.

[0125] Regarding eddy current sensors 3-6:

[0126] 1) During the installation process, the eddy current sensor is first calibrated using an in-situ calibration sensor;

[0127] 2) Linearity calibration was performed using -2V voltage as the starting point and -18V voltage as the ending point;

[0128] 3) Input the calibration data into the signal processor for sensor calibration.

[0129] The base 3-1 is preferably a magnetic base;

[0130] The column 3-4 is parallel to the main shaft 5, and the eddy current sensor 3-6 is a strip structure with the detection end of the eddy current sensor close to the main shaft 5.

[0131] Among them, the sensor fixing column is used for the calibrated eddy current sensor to measure the gap displacement between the sensor and the main shaft of the unit.

[0132] A circular hole is provided through the upper end of the column 3-4. The eddy current sensor is connected to the circular hole laterally and fixed to the upper end of the column 3-4 by fixing nut 3-5.

[0133] Regarding the high-precision translation platform, the high-precision translation platform 3-2 can drive the column 3-4 to move in the X / Y direction.

[0134] The high-precision translation platform 3-2 includes an X-axis adjustment module, a Y-axis adjustment module, and adjustment knobs 3-3. The X-axis adjustment module can generate precise X-axis displacement through the X-axis coarse adjustment knob and the X-axis fine adjustment knob, and the Y-axis adjustment module can generate precise Y-axis displacement through the Y-axis coarse adjustment knob and the Y-axis coarse adjustment knob.

[0135] The high-precision horizontal translation platform features a horizontal position adjustment device that allows for small-range manual adjustment in both horizontal directions. This device also includes a high-precision measuring scale, enabling the reading of parameters such as the adjustment range and distance, with an accuracy of 0.1µm. The high-precision horizontal translation platform is horizontally fixed to a support or other stationary component via a base.

[0136] The column is fixed to a horizontal translation platform. The position of the force column is adjusted by adjusting the knobs on the platform, thereby adjusting the gap between the sensor and the main shaft. The size of the gap can be read using a high-precision measuring scale built into the device.

[0137] To facilitate better and more accurate understanding and implementation by technical personnel, the following parameters are provided for the high-precision translation platform:

[0138] 1) Model designation: XYW60H-13U;

[0139] 2) Two-dimensional ultra-precision translation stage with a table size of 60×60mm and a stroke of 13mm.

[0140] 3) The sliding structure adopts a cross roller guide structure, which has a greater load-bearing capacity and better stability and smoothness of movement.

[0141] 4) Precision two-stage adjustment, micron head adjustment, can read the value, minimum resolution: 0.1um.

[0142] 5) The bottom of the platform has mounting holes, which can be easily installed on other platforms, or a separate mounting base plate can be provided for downward installation.

[0143] 6) Alloy aluminum, with black anodized surface. Stainless steel translation stages are also available upon special request.

[0144] Furthermore, the signal terminal of the eddy current sensor 3-6 is connected to the acquisition unit via cable 3-7, and the acquisition unit is connected to the data processing unit via wired / wireless connection.

[0145] The output signal of the calibrated eddy current sensor is connected to the acquisition device for continuous acquisition, and then transmitted to the data processing unit via a wireless network.

[0146] To facilitate better and more accurate understanding by technical personnel and to expedite implementation, the parameters provided for the acquisition device and data processing unit are as follows:

[0147] The DMS-16CLD wireless acquisition unit can be selected. It features a compact structure and small size, consisting of a power module, acquisition and processing module, and wireless transceiver module. Each channel of the node has an independent high-precision amplification and conditioning circuit, compatible with various types of sensors, such as displacement, acceleration, pressure, and temperature sensors. The node supports 2-wire, 3-wire, and 4-wire input methods. Acquired data can be wirelessly transmitted to a computer in real time or stored in the node's built-in 2G data storage, ensuring data accuracy. Communication is via WiFi, which offers high bandwidth and an over-the-air transmission rate of up to 11MB / s, fully meeting the data communication requirements of multi-channel high-speed continuous acquisition. Under signal relay conditions, the effective transmission distance can exceed 500m.

[0148] The data processing unit can be a data processing computer, such as a laptop computer;

[0149] It also includes a battery that can provide power to the eddy current sensor and the wireless acquisition unit itself, and the battery can be built into the wireless acquisition unit.

[0150] When calibrating the sensitivity coefficient of an eddy current sensor using this invention, the following steps are performed:

[0151] 1) Fix the in-situ calibration device 3 near the measurement part of the sensor; then fix the eddy current sensor on the in-situ calibration device 3, connect the output signal of the calibrated eddy current sensor to the acquisition device of this layer, and provide power to the sensor.

[0152] 2) After the above preparations are completed, the distance between the eddy current sensor and the spindle is adjusted by a high-precision translation platform. The voltage / current signal output by the calibrated sensor is automatically recorded by the signal processing computer. In addition, the high-precision scale data on the in-situ calibration device is read manually to calculate the gap adjustment value between the eddy current sensor and the spindle, and the data is synchronously input into the computer.

[0153] 3) After obtaining signals and data from multiple displacement points through the above steps, the signal processing computer uses the least squares method to calculate the sensitivity coefficient of the calibrated sensor.

[0154] 4) Using the obtained sensitivity coefficient to be calibrated, adjust the distance between the spindle surface and the sensor. At the same time, record the displacement output measured by the eddy current sensor and the actual displacement measured manually, and compare the error between the two point by point to form an error analysis report. If the error between the two is within the allowable range, the online calibration is completed, and the sensitivity coefficient to be calibrated is the sensitivity coefficient of the eddy current sensor used in this system.

[0155] The above system can be used to obtain the characteristic parameters of the shaft system of a hydro-generator unit; it can also be used in the adjustment of the shaft system of a hydro-generator unit; the following is a specific introduction to the adjustment of the shaft system of a mixed-flow hydro-generator unit:

[0156] A method for adjusting the shaft system of a mixed-flow hydro-generator unit includes the following steps:

[0157] Step 1: Measure the relevant data for the turning gear;

[0158] Step 2: Resample by principal axis phase;

[0159] Step 3: Obtain the spindle runout during the turning process;

[0160] Step 4: Obtain the levelness of the mirror plate during the turning process;

[0161] Step 5: Obtain the unit's rotation center data;

[0162] Step 6: Obtain the shaft system adjustment plan;

[0163] In step 5, the mixed-flow unit mainly measures the air gap between the upper and lower layers of the stator and rotor, and the gap between the upper and lower sealing rings of the impeller.

[0164] In step 1, before the turning operation begins, all sway sensor measurements are zeroed. During the turning operation, the X-axis sway measurement value AX is acquired. α1 ~AX αn Y-axis swing measurement value AY α1 ~AY αn 1. Mirror plate levelness measurement value; 2. G value of the gap between rotating and fixed parts. α1 ~G αn ;

[0165] In step 2, the data collected by all sensors during one revolution of the rotating shaft are resampled according to the rotation angle of the main shaft. The number of equally divided points is an even number n. The first point after resampling is the starting point. Then, the angle value corresponding to a certain point i (i∈[0,n]) is:

[0166]

[0167] In step 3, the methods of turning the car include fixed-point turning and continuous turning;

[0168] For the fixed-point wheel rotation method, the following steps are adopted:

[0169] After resampling all swing values ​​at the X-azimuth and Y-azimuth measuring points of a certain cross section, vector decomposition is performed into X-axis and Y-axis components. Then, the vector component X of the X-azimuth measuring point of this cross section is... x X y and the vector component Y of the Y-axis measuring point x Yy for:

[0170]

[0171]

[0172]

[0173]

[0174] Calculate the offset coordinates X and Y of the geometric center of the rotating component relative to the center of rotation:

[0175] X = (X x +Y x ) / 2

[0176] Y = (X y +Y y ) / 2

[0177] The offset coordinates of the geometric center of each rotating component relative to the center of rotation were calculated as follows:

[0178] X 上导 Y 上导 X 下导 Y 下导 X 法兰 Y 法兰 X 水导 Y 水导

[0179] After the center deviation of the axis of each section is calculated, the swing value at the limit of horizontal displacement needs to be deducted when calculating the swing. The center deviation of the axis of each section needs to be deducted from the displacement at the lower guide.

[0180] X′ 上导 =X 上导 -X 下导 ,Y′ 上导 =Y 上导 -Y 下导

[0181] X′ 法兰 =X 法兰 -X 下导 ,Y′ 法兰 =Y 法兰 -Y 下导

[0182] X′ 水导 =X 水导 -X 下导 ,Y′ 水导 =Y 水导 -Y 下导

[0183] The sway and orientation of each section are as follows:

[0184] Swing:

[0185] Swing azimuth angle:

[0186] In step 3, for the continuous turning gear method, the following steps are adopted:

[0187] Method 1: The total runout value is calculated by subtracting the phases from the opposite side during continuous turning. Since the rotation phase is continuous during continuous turning, the maximum total runout that actually occurs during the rotation of the rotating component can be captured. The computer sets the spindle X-direction displacement value X corresponding to angle αi and αi+180°. αi and the Y-direction axial movement value Y αi for:

[0188] X αi =AX( αi+180° )-AX αi αi∈[0, 180°]

[0189] Y αi =AY( αi+180° )-AY αi αi∈[0, 180°]

[0190] The angle αi corresponds to the full swing R. αi for:

[0191]

[0192] After calculating the total runout at all angles of each cross section, when calculating the net runout of the upper guide and water guide, the runout value at the corresponding angle-limited horizontal displacement point (lower guide) needs to be deducted. The maximum total runout amplitude and net runout amplitude are then found in the upper and water guide runouts; these are the maximum double amplitude values ​​for the turning gear, and the corresponding angle is the angle with the maximum double amplitude value. To check the concentricity of the upper shaft and rotor flange, the relative net runout value, calculated by subtracting the total runout of the lower rotor flange from the total runout of the upper guide, also needs to be calculated.

[0193] Method 2: The algorithm is the same as the fixed-point turning method mentioned above. The angle is calculated in equal parts, with each point being 0.5°.

[0194] In step 4, when calculating the mirror plate levelness during the turning process, the tilt angle data collected by the mirror plate leveling sensor is decomposed into X and Y vectors. For example, at mirror plate angle αi, the collected tilt angle data β αi Decomposed into X-direction vector β αiX and the Y-direction vector β αiY for:

[0195] β αiX=β αi cosαi;αi∈[0,360)

[0196] β αiY =β αi sinαi;αi∈[0,360)

[0197] The tilt angle X and direction vector β of the plane measured by the horizontal sensor during one revolution of the unit X and the Y vector β X The calculation method is as follows:

[0198]

[0199]

[0200] The calculation methods for inclination angle β and azimuth angle θ are as follows:

[0201]

[0202]

[0203] Then the horizontal azimuth angle of the mirror plate is θ, and the horizontality H (mm / m) is:

[0204] H = tgβ × 1000; (mm / m).

[0205] In step 5, during the turning process, the clearance values ​​of various parts between the rotating and stationary components of the unit are measured. The rotation center of the unit is calculated. For mixed-flow units, the main measurements are the air gap between the upper and lower layers of the stator and rotor, and the gap between the upper and lower sealing rings of the impeller.

[0206] When rotating the machine, it is necessary to measure the gap between the fixed and rotating parts at 0° and 180° positions, and then decompose them into vectors in the X and Y directions.

[0207] At 0°, the eccentricities X0 and Y0 of the geometric center of the rotating component relative to the fixed component are:

[0208]

[0209]

[0210] At 180°, the eccentricity X of the geometric center of the rotating component relative to the fixed component 180 and Y 180 for:

[0211]

[0212]

[0213] The coordinates of the fixed component relative to the rotation center and the eccentricities X1 and Y1 are:

[0214] X1 = -(X0 + X 180 ) / 2

[0215] Y1 = -(Y0 + Y 180 ) / 2

[0216] Eccentricity:

[0217] Off-center orientation:

[0218] The geometric center of the 0° azimuth rotating component is relative to the rotation center in coordinates X2 and Y2 as follows:

[0219] X2=(X0-X 180 ) / 2

[0220] Y2=(Y0-Y 180 ) / 2

[0221] Eccentricity value:

[0222] Off-center orientation:

[0223] The yaw coordinates X3 and Y3 of the rotating component are:

[0224] X3 = -2 * X2

[0225] Y3 = -2 * Y2

[0226] Swing value:

[0227] Swing direction:

[0228] In step 6, the following steps are adopted when obtaining the shaft system adjustment scheme for the mixed-flow turbine unit:

[0229] 1) Obtain a plan for leveling the mirror plate;

[0230] 2) Obtain the axis adjustment plan;

[0231] 3) Obtain the rotation center adjustment plan;

[0232] In step 1), when obtaining the mirror plate leveling adjustment scheme;

[0233] Let there be N support bolts for the mirror plate, R be the distance from the installation position of the support bolt to the center of the mirror plate, L be the levelness of the mirror plate, and θ be the azimuth angle.

[0234] Then, the adjustment amount A of the support bolt at angle α. α The calculation formula is:

[0235] Aα = -R×L×cos(β-α);

[0236] In step 2), when obtaining the axis adjustment scheme;

[0237] The displacement value of the thrust is deducted from the sway of each section, and the geometric center coordinate X of the upper guide measurement surface is calculated. 上导 Y 上导 The geometric center coordinates X of the rotor lower flange measuring surface 下法兰 Y 下法兰 Geometric center coordinates X of water conduction measurement surface 水导 Y 水导 The upper guide relative to the center coordinate X of the rotor's lower flange 上导-下法兰 Y 上导-下法兰 ;

[0238] When the geometric center coordinates of the upper guide measuring surface are too large, it is necessary to comprehensively analyze the center coordinates of the upper guide relative to the lower flange of the rotor.

[0239] 1) If X 上导-下法兰 Y 上导-下法兰 If the value is too large, it indicates a significant misalignment between the upper shaft and the rotor flange, requiring adjustment. The adjustment value and direction are given by the following formula:

[0240] Adjustment value:

[0241] Adjust orientation:

[0242] 2) If X 上导-下法兰 Y 上导-下法兰 If the value is too small, it means that the relative position of the thrust head and the rotor needs to be adjusted. In this case, it is necessary to combine the data of the water guide geometric center to make the adjustment, and adjust the rotation center of the unit to the middle position between the water guide geometric center and the upper guide geometric center.

[0243] In step 3), when obtaining the rotation center adjustment scheme;

[0244] The adjustment of the rotation center involves calculating and analyzing the gap values ​​between the fixed and rotating components at each section, obtaining the coordinates of the geometric center of the fixed component relative to the rotation center of the rotating component. This coordinate serves as the basis for the horizontal pushing of the main shaft. By horizontally pushing the shaft, the gaps at each section are adjusted to the optimal range. Before calculating the pushing scheme, the adjustment range and priority of the gap values ​​for each end face are set according to the actual situation of the unit. The priority of the gap values ​​is divided into two levels: critical gap values ​​refer to the gap values ​​that must be adjusted to the optimal level while only meeting the standards for other gap values; and ordinary gap values ​​refer to the gap values ​​that only need to meet the standards.

[0245] The system's spindle push calculation method relies on the computer's high-speed computing power. The available options are: perform trial pushes in each of the 360° directions of the spindle, with an angle step of 1°. The trial push amount ranges from 0mm to 10mm, with a step size of 0.001mm. The system first selects the spindle push scheme from numerous trial push schemes where the clearance values ​​of all parts meet the standards. Then, it identifies the scheme with the optimal priority clearance value among these schemes as the recommended scheme.

[0246] This invention also provides a method for calculating the sway of a fixed-point turning gear, which includes the following steps:

[0247] 1. After resampling the X-axis and Y-axis measuring points of a certain cross section, all swing values ​​are vector decomposed into X-axis and Y-axis components;

[0248] 2. Calculate the offset coordinates X and Y of the geometric center of the rotating component relative to the center of rotation;

[0249] 3. Calculate the offset coordinates of the geometric center of each rotating component relative to the center of rotation;

[0250] 4. After the center deviation of the axis of each section is calculated, the swing value at the limit of horizontal displacement needs to be deducted when calculating the swing to obtain the swing and orientation of each section.

[0251] In step 1, the vector component X of the X-axis measuring point of the cross section is... x X y and the vector component Y of the Y-axis measuring point x Y y for:

[0252]

[0253]

[0254]

[0255]

[0256] In step 2, the offset coordinates X and Y of the geometric center of the rotating component relative to the rotation center are calculated as follows:

[0257] X = (X x +Y x ) / 2

[0258] Y = (X y +Y y ) / 2;

[0259] In step 3, the offset coordinates of the geometric center of each rotating component relative to the rotation center are calculated as follows:

[0260] X上导 Y 上导 X 下导 Y 下导 X 法兰 Y 法兰 X 水导 Y 水导

[0261] In step 4, after the center deviation of each section axis is calculated, the swing value at the limit horizontal displacement needs to be deducted when calculating the swing, and the displacement at the lower guide needs to be deducted when calculating the center deviation of each section axis.

[0262] X′ 上导 =X 上导 -X 下导 ,Y′ 上导 =Y 上导 -Y 下导

[0263] X′ 法兰 =X 法兰 -X 下导 ,Y′ 法兰 =Y 法兰 -Y 下导

[0264] X′ 水导 =X 水导 -X 下导 ,Y′ 水导 =Y 水导 -Y 下导

[0265] The sway and orientation of each section are as follows:

[0266] Swing:

[0267] Swing azimuth angle:

[0268] This invention also includes a method for calculating the sway of a continuous turning gear, which includes the following steps:

[0269] Step 1: Calculate the total sway value by subtracting the values ​​from the opposite side during continuous turning.

[0270] Step 2: After calculating the full swing at all angles of each cross section, obtain the net swing values ​​of the upper guide and the water guide;

[0271] Step 3: Find the maximum full swing amplitude and net swing amplitude in the upper guide and water guide swing. These are the maximum double amplitude values ​​of the turning gear, and the corresponding angle is the maximum double amplitude angle.

[0272] In step 1, the following steps are used to obtain the full swing value:

[0273] The displacement value X of the main shaft in the X direction corresponding to angle αi and αi+180° of the computer group αi and the Y-direction axial movement value Y αi for:

[0274] X αi =AX( αi+180° )-AX αi αi∈[0, 180°]

[0275] Y αi =AY( αi+180° )-AY αi αi∈[0, 180°]

[0276] The angle αi corresponds to the full swing R. αi for:

[0277]

[0278] This invention also includes a method for adjusting the shaft system of a mixed-flow turbine unit, comprising the following steps:

[0279] 1. Obtain a plan for leveling the mirror plate;

[0280] 2. Obtain the axis adjustment plan;

[0281] 3. Obtain the rotation center adjustment plan;

[0282] In step 1, when obtaining the mirror plate leveling adjustment plan;

[0283] Let there be N support bolts for the mirror plate, R be the distance from the installation position of the support bolt to the center of the mirror plate, L be the levelness of the mirror plate, and θ be the azimuth angle.

[0284] Then, the adjustment amount A of the support bolt at angle α. α The calculation formula is:

[0285] A α = -R×L×cos(β-α);

[0286] In step 2, when obtaining the axis adjustment plan;

[0287] The displacement value of the thrust is deducted from the sway of each section, and the geometric center coordinate X of the upper guide measurement surface is calculated. 上导 Y 上导 The geometric center coordinates X of the rotor lower flange measuring surface 下法兰 Y 下法兰 Geometric center coordinates X of water conduction measurement surface 水导 Y 水导 The upper guide relative to the center coordinate X of the rotor's lower flange 上导-下法兰 Y 上导-下法兰 ;

[0288] When the geometric center coordinates of the upper guide measuring surface are too large, it is necessary to comprehensively analyze the center coordinates of the upper guide relative to the lower flange of the rotor.

[0289] 1) If X 上导-下法兰 Y 上导-下法兰 If the value is too large, it indicates a significant misalignment between the upper shaft and the rotor flange, requiring adjustment. The adjustment value and direction are given by the following formula:

[0290] Adjustment value:

[0291] Adjust orientation:

[0292] 2) If X 上导-下法兰 Y 上导-下法兰 If the value is too small, it means that the relative position of the thrust head and the rotor needs to be adjusted. In this case, it is necessary to combine the data of the water guide geometric center to make the adjustment, and adjust the rotation center of the unit to the middle position between the water guide geometric center and the upper guide geometric center.

[0293] In step 3, when obtaining the rotation center adjustment scheme;

[0294] The adjustment of the rotation center involves calculating and analyzing the gap values ​​between the fixed and rotating components at each section, obtaining the coordinates of the geometric center of the fixed component relative to the rotation center of the rotating component. This coordinate serves as the basis for the horizontal pushing of the main shaft. By horizontally pushing the shaft, the gaps at each section are adjusted to the optimal range. Before calculating the pushing scheme, the adjustment range and priority of the gap values ​​for each end face are set according to the actual situation of the unit. The priority of the gap values ​​is divided into two levels: critical gap values ​​refer to the gap values ​​that must be adjusted to the optimal level while only meeting the standards for other gap values; and ordinary gap values ​​refer to the gap values ​​that only need to meet the standards.

[0295] When obtaining the optimal adjustment scheme, trial push calculations are performed in each of the 360° directions of the main shaft. Appropriate angles are selected to calculate the step size, trial push amount, and trial push step size. First, the shaft pushing scheme in which the clearance values ​​of each part meet the standard is selected from many trial push schemes. Then, the scheme with the optimal clearance value at the critical level is selected as the final adjustment scheme.

[0296] This is optional, with an angle step size of 1°. The trial push amount ranges from 0mm to 10mm, with a trial push step size of 0.001mm.

Claims

1. A method for calculating the levelness of a mirror plate during the turning process, characterized in that, It employs the following method: At any position on the mirror plate, the tilt angle data collected by the horizontal measurement sensor is decomposed into X and Y vectors, specifically at the mirror plate angle. Next, collect tilt angle data. And decomposed into the X-direction vector and the Y-direction vector : ； ； The tilt angle X direction vector of the plane measured by the horizontal sensor during one revolution of the unit and the Y-direction vector The calculation method is as follows: ； ； Then the angle of inclination and azimuth The calculation method is as follows: ； ； The horizontal azimuth angle of the mirror plate is level H for: ； Among them, levelness H The unit is mm / m.

2. The method according to claim 1, characterized in that, In obtaining level H Next, adjust the mirror plate to be level, as follows: Assume there are N support bolts for the mirror plate, R is the distance from the bolt installation position to the center of the mirror plate, and the levelness of the mirror plate is... H The azimuth angle is θ; Then, the adjustment amount A of the support bolt at angle α. α The calculation formula is: ； Adjust the mirror plate to make it level by adjusting each support bolt.

3. The method according to claim 2, characterized in that, After the mirror plate is leveled, the axis adjustment plan is obtained, as follows: The displacement value of the thrust is deducted from the sway of each section, and the geometric center coordinate X of the upper guide measurement surface is calculated. 上导 Y 上导 The geometric center coordinates X of the rotor lower flange measuring surface 下法兰 Y 下法兰 Geometric center coordinates X of water conduction measurement surface 水导 Y 水导 The upper guide relative to the center coordinate X of the rotor's lower flange 上导-下法兰 Y 上导-下法兰 ; When the geometric center coordinates of the upper guide measuring surface are too large, it is necessary to comprehensively analyze the center coordinates of the upper guide relative to the lower flange of the rotor. 1) If X 上导-下法兰 Y 上导-下法兰 If the value is too large, it indicates that the upper shaft and the upper flange of the rotor are significantly misaligned, requiring adjustment. The adjustment value and direction are given by the following formula: Adjustment value: ; Adjust orientation: ; 2) If X 上导-下法兰 Y 上导-下法兰 If the value is too small, it means that the relative position of the thrust head and the rotor needs to be adjusted. In this case, it is necessary to combine the data of the water guide geometric center to make the adjustment, and adjust the rotation center of the unit to the middle position between the water guide geometric center and the upper guide geometric center.

4. The method according to claim 3, characterized in that, After obtaining the axis adjustment scheme, obtain the rotation center adjustment scheme, as follows: The adjustment of the rotation center involves calculating and analyzing the gap values ​​between the fixed and rotating components of each section to obtain the coordinates of the geometric center of each fixed component relative to the rotation center of the rotating component. This coordinates serve as the basis for the horizontal pushing of the main shaft. By pushing the shaft horizontally, the gaps of each section are adjusted to the optimal range. Before calculating the pushing scheme, the adjustment range and priority of the gap values ​​of each end face are set according to the actual situation of the unit. The priority of the gap values ​​is divided into two levels: the critical level gap value refers to the gap value that must be adjusted to the optimal level on the basis that other gap values ​​only meet the standards; the ordinary level gap value refers to the gap value that only meets the standards. When obtaining the optimal adjustment scheme: perform trial push calculations in each of the 360° directions of the main shaft, select appropriate angles to calculate the step size, trial push amount, and trial push step size; firstly, select the shaft pushing scheme in which the gap values ​​of each part meet the standard from many trial push schemes, and then find the scheme with the optimal key level gap value as the final adjustment scheme.

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