A multi-channel intelligent ultrasonic hydraulic wrench tightening system

Abstract

The application relates to the technical field of overhauling and maintaining wind generating sets, and discloses a multi-channel intelligent ultrasonic hydraulic wrench fastening system. The multi-channel intelligent ultrasonic hydraulic wrench fastening system has the advantages that a pre-tightening force value can be set through a control panel, the value is transmitted to a feedback operation unit through a network, the feedback operation unit calculates a standard tight force value according to the set pre-tightening force value, and the value is transmitted to a controller through the network; an ultrasonic sensor is introduced and installed on a workbench around a bolt, the axial pre-tightening force of the bolt is measured in real time during the tightening process, and the axial pre-tightening force is fed back to an electro-hydraulic servo system to control the ultrasonic hydraulic wrench to tighten; since the direct axial force is measured, the influence factors such as friction of a threaded pair and connection end face errors are avoided, high-precision bolt axial force control is realized, the bolt fastening operation is truly constructed by using the symmetry method, the axial force is accurately controllable, and the data is consistent with the actual reality.

Description

Technical Field

[0001] This invention relates to the field of wind turbine generator maintenance technology, specifically a multi-channel intelligent ultrasonic hydraulic wrench tightening system. Background Technology

[0002] To achieve lower cost per kilowatt-hour, wind turbine towers and blades are becoming increasingly larger (length, chord length, weight). Wind turbine stability is becoming more sensitive to the precision of blade manufacturing, installation, and control. These factors ultimately manifest as aerodynamic imbalances, affecting wind turbine vibration, load, and power generation. This necessitates uniform force distribution during bolt tightening.

[0003] With the rapid development of the wind power industry and the continuous increase in the size of wind turbines, the high-strength bolts connecting various components of the wind turbine are facing severe challenges, with frequent loosening and breakage problems. This has led to serious accidents such as the falling of large components of the wind turbine or even tower collapse, causing significant property losses to wind farms.

[0004] Currently, the wind power industry primarily uses the torque method for construction, where a passing torque is considered sufficient for acceptance. However, the torque method is limited by its underlying principle, making it difficult to control the consistency of the friction coefficient. This results in significant dispersion of bolt axial force after tightening, potentially leading to substandard axial force. While torque-based tightening requires strict process control, the sheer number of controllable factors and the lack of instruments for rapid post-installation verification of tightening quality (axial force) make it easy for contractors to overlook installation quality. A problem in any stage can result in substandard axial force.

[0005] In short, only by directly measuring the axial force can the actual situation of the bolted connection be accurately known; that is, only when the axial force is qualified can the connection be proven to be qualified. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a multi-channel intelligent ultrasonic hydraulic wrench tightening system. It features a control panel for setting a preload value, which is then transmitted via network to a feedback calculation unit. This unit calculates the standard tightening force based on the set preload value and transmits it to a controller via the network. An ultrasonic sensor, mounted on a worktable around the bolt, measures the bolt's axial preload in real time during tightening and feeds it back to the electro-hydraulic servo system, controlling the ultrasonic hydraulic wrench to apply the tightening force. Because it measures the direct axial force, it avoids the influence of errors caused by friction in the threaded joint and the connecting end face, achieving high-precision bolt axial force control. This system truly enables symmetrical bolt tightening operations, precise and controllable axial force, and data that accurately reflects actual conditions, thus solving the aforementioned problems.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a multi-channel intelligent ultrasonic hydraulic wrench fastening system, comprising a parameter adjustment panel, bolts, an ultrasonic hydraulic wrench, a feedback calculation unit, a controller, a hydraulic pump, an ultrasonic sensor, and an ultrasonic force measuring unit; The parameter adjustment panel is used to set the preload value. And transmit the value to the feedback processing unit via the network; The feedback calculation unit calculates the preload value according to the set preload value. Calculate the standard tightening force value The value is then transmitted to the controller via the network. The controller is based on the standard tension value transmitted by the feedback processing unit. Control and adjust the pressure of the hydraulic pump; The ultrasonic sensor is used to measure and calculate the axial preload of the bolt in real time during the bolt tightening process. This value is then fed back to the electro-hydraulic servo system to tighten the bolts; The hydraulic pump is an electro-hydraulic servo system, and the hydraulic pump operates based on the value of the bolt axial preload. Control the ultrasonic hydraulic wrench to tighten the bolts; The ultrasonic force measuring unit is used to measure the force output by the ultrasonic hydraulic wrench, including the tensile force during tightening. With compressive force .

[0008] A workbench is located around the bolt, and an ultrasonic sensor is mounted on the workbench.

[0009] Preferably, the parameter adjustment panel uses an LCD screen, allowing the operator to input the preload value via a visual interface. set up.

[0010] Preferably, the feedback calculation unit calculates the preload value according to the set preload value. Calculate the standard tightening force value The calculation formula is as follows: In the company, Indicates the standard tightening force value. Indicates the preload value. Indicates the coefficient of friction. The cross-sectional area of ​​the bolt is indicated. The coefficient of friction and cross-sectional area are obtained from the bolt material data table.

[0011] Preferably, the controller uses the standard tension value transmitted by the feedback calculation unit. The pressure of the hydraulic pump is controlled and adjusted using the following method: The hydraulic pump calculates and adjusts its output pressure based on the control strategy within the control algorithm. This algorithm is a PID controller used to adjust the hydraulic pump's pressure output based on system feedback.

[0012] Preferably, the hydraulic pump belongs to an electro-hydraulic servo system, which is a system that combines electrical and hydraulic control technologies to achieve precise position, speed and force control. By controlling the electric motor to drive the hydraulic pump, the movement of the hydraulic actuator is controlled, thereby achieving precise positioning, motion control and force control of the mechanical system.

[0013] Preferably, a workbench is provided around the bolt, and an ultrasonic sensor is mounted on the workbench to simultaneously detect the tightness of two or more bolts.

[0014] Preferably, the ultrasonic sensor is used to measure and calculate the axial preload of the bolt in real time during the bolt tightening process. The calculation formula is as follows: In the formula, Indicates the axial preload of the bolt. This indicates the bolt preload factor, which depends on factors such as the bolt material, thread type, and lubrication conditions. It can be obtained from relevant standards in bolt design manuals. This indicates the axial tensile force applied to the bolt, a value that can be automatically obtained by the system.

[0015] Preferably, the electro-hydraulic servo system is based on the bolt axial preload. The value is controlled by an ultrasonic hydraulic wrench to tighten the bolts. The tightening process is as follows: Based on the measured axial preload The tightening torque output of the ultrasonic hydraulic wrench is controlled by an electro-hydraulic servo system. During the tightening process, the system monitors the axial preload of the bolt in real time and adjusts the torque according to the preset preload value. Adjust the output of the hydraulic system to ensure that the bolts are tightened to the set preload level.

[0016] Preferably, the ultrasonic force measuring unit is used to measure the tensile force output by the ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: ;In the formula, This indicates the tensile force output by the ultrasonic hydraulic wrench during tightening. This indicates the tightening pressure output by the ultrasonic hydraulic wrench; this value is automatically obtained by the system. This represents the effective force-measuring area of ​​the ultrasonic force-measuring unit, and the formula for calculating this area is: , The radius of the hole for all bolts being tightened. This indicates the preset preload value.

[0017] Preferably, the ultrasonic force measuring unit is used to measure the compressive force output by the ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: ;In the formula, This indicates the compressive force output by the ultrasonic hydraulic wrench during tightening. , This indicates the weight of the bolts that the hydraulic wrench needs to tighten. This indicates the cross-sectional area of ​​the fastening bolt.

[0018] Compared with the prior art, the present invention provides a multi-channel intelligent ultrasonic hydraulic wrench fastening system, which has the following beneficial effects: 1. It avoids the shortcomings of ordinary hydraulic wrenches that tighten according to torque values, and adopts the method of directly measuring axial force to accurately reflect the stress on the bolt.

[0019] 2. Use dual-channel or multi-channel, symmetrical or star-shaped construction to ensure that the axial force on the entire flange surface is balanced when the bolts are tightened.

[0020] 3. It has a matching mobile (PC) application, which makes it convenient to observe data during construction. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the system connection principle of the present invention; Figure 2 This is a schematic diagram of the construction principle of the present invention; Figure 3 This is the mobile interface for the ultrasonic hydraulic wrench of this invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The purpose of this invention is to provide a multi-channel intelligent ultrasonic hydraulic wrench tightening system that solves the practical engineering problems of unsatisfactory bolt preload accuracy and consistency caused by the traditional torque method, achieving high-precision bolt axial force control. To this end, a multi-channel intelligent ultrasonic hydraulic wrench tightening system is proposed, based on... Figure 1 As shown, the system includes bolts, an ultrasonic hydraulic wrench, a feedback processing unit, a controller, a hydraulic pump, an ultrasonic sensor, and an ultrasonic force measuring unit, wherein: The parameter adjustment panel uses an LCD screen, allowing operators to set the preload value via a visual interface. The value is set and transmitted to the feedback calculation unit via the network.

[0024] The feedback calculation unit calculates the preload value based on the set preload value. Calculate the standard tightening force value The calculation formula is as follows: During the production process, ensuring the correct tightening level can reduce damage to parts caused by insufficient or excessive tightening, thereby saving on repair or replacement costs. In the formula, Indicates the standard tightening force value. Indicates the preload value. Indicates the coefficient of friction. The cross-sectional area of ​​the bolt is indicated. The coefficient of friction and the cross-sectional area are obtained from the bolt material data table. By applying the standard tightening force correctly, excessive stress or damage due to loosening can be avoided during product use, which helps to extend the product's service life.

[0025] Hydraulic pumps belong to electro-hydraulic servo systems, which are systems that combine electrical and hydraulic control technologies to achieve precise position, speed, and force control. By controlling the electric motor to drive the hydraulic pump, the movement of the hydraulic actuator is controlled, thereby achieving precise positioning, motion control, and force control of the mechanical system.

[0026] By installing ultrasonic sensors on the workbench around the bolt, the axial preload of the bolt is measured and calculated in real time during the tightening process. The calculation formula is as follows: The axial preload of the bolt ensures that the threaded connection will not loosen or fail when subjected to external forces or vibrations, thus guaranteeing the safety performance of the connection. In the formula, Indicates the axial preload of the bolt. This indicates the bolt preload factor, which depends on factors such as the bolt material, thread type, and lubrication conditions. It can be obtained from relevant standards in bolt design manuals. This indicates the axial tensile force applied to the bolt, a value that can be automatically obtained by the system.

[0027] Accurate calculation of bolt axial preload can help achieve uniform force distribution between bolts and avoid premature fatigue damage caused by uneven force distribution on some bolts.

[0028] The ultrasonic sensor feeds back the calculated axial preload of the bolt to the electro-hydraulic servo system. This system is responsible for controlling the ultrasonic hydraulic wrench to tighten the bolt according to the axial preload, achieving precise control of the bolt tightening force and avoiding bolt loosening due to insufficient tightening force, which could lead to connection errors.

[0029] The ultrasonic force measuring unit is used to measure the tensile force output by the ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: By calculating the tensile force output by the ultrasonic hydraulic wrench during tightening, it can be ensured that the bolt or nut receives the correct preload, thus avoiding over-tightening or under-tightening. In the formula, This indicates the tensile force output by the ultrasonic hydraulic wrench during tightening. This indicates the tightening pressure output by the ultrasonic hydraulic wrench; this value is automatically obtained by the system. This represents the effective force-measuring area of ​​the ultrasonic force-measuring unit, and the formula for calculating this area is: , The radius of the hole for all bolts being tightened. This indicates the initial preload value. Calculating the tensile force ensures that the connector will not experience thread loosening or fatigue fracture when subjected to working loads, thus improving the safety performance of the connector.

[0030] The ultrasonic force measuring unit is used to measure the compressive force output by an ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: Using an ultrasonic force measuring unit allows for real-time monitoring of the compressive force generated during the tightening process, ensuring that each tightening point reaches the required preload level. In the formula, This indicates the compressive force output by the ultrasonic hydraulic wrench during tightening. This indicates the weight of the bolts that the hydraulic wrench needs to tighten. This indicates the cross-sectional area of ​​the fastening bolt. By measuring the compressive force, the fastening parameters can be adjusted and optimized based on the actual data to achieve better fastening results and a longer lifespan for the connector.

[0031] Ultrasonic hydraulic wrenches are high-precision tightening tools designed for industrial applications. They solve the practical engineering problems of unsatisfactory bolt preload accuracy and consistency caused by traditional torque methods. By introducing ultrasonic sensors installed on a worktable around the bolt, the axial preload of the bolt is measured in real time during tightening and fed back to the electro-hydraulic servo system to control the tightening of the ultrasonic hydraulic wrench. Because it measures the direct axial force, it avoids the influence of errors such as friction of the threaded pair and the connection end face, achieving high-precision bolt axial force control. Using ultrasonic hydraulic wrenches, dual-channel dual-wrench diagonal or four-channel four-wrench star-shaped wrenches can be used for symmetrical construction of fixed axial force on the fan body. Two or more bolts can be tightened simultaneously in a short time. The axial force is tested in real time, and the synchronization control accuracy is high, ensuring that the axial force of the entire flange surface is balanced and qualified. Real-time application and real-time reading truly enable symmetrical construction and precise control of axial force in bolt tightening operations.

[0032] like Figure 2 As shown, the use of the star-shaped fixed axial force construction method can revolutionarily replace the traditional multi-step progressive torque construction method, truly achieving efficient multi-point application on the same flange surface, fixed axial force application, "hitting wherever you point", effectively implementing the design force value required by the designer, and ensuring that the data is consistent with the actual situation. During testing, the bolt axial force is directly measured, avoiding the phenomenon of bolt torque balance but bolt axial force imbalance caused by uneven lubrication.

[0033] like Figure 3 As shown, the status of the hydraulic wrench during operation can be displayed on a mobile phone, allowing staff to monitor it in real time. When abnormalities occur, the working parameters of the hydraulic wrench can be adjusted in a timely manner to ensure the qualified rate of the bolts tightened by the hydraulic wrench.

[0034] This system directly measures the bolt axial force during testing, avoiding the phenomenon of bolt torque balance but bolt axial force imbalance caused by uneven lubrication. At the same time, it adopts a dual (multi) channel method. When the wind turbine is used for annual bolt tightening maintenance, it adopts the physical fixed axial force symmetrical method to complete the construction of 2 or more bolts simultaneously and in a short time. The synchronization control accuracy is high, and the real-time application and reading are real-time, which truly enables the bolt tightening operation to achieve symmetrical construction, precise and controllable axial force, and data that is consistent with the actual situation.

[0035] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-channel intelligent ultrasonic hydraulic wrench fastening system, characterized in that: It includes a parameter adjustment panel, bolts, an ultrasonic hydraulic wrench, a feedback calculation unit, a controller, a hydraulic pump, an ultrasonic sensor, and an ultrasonic force measurement unit; The parameter adjustment panel is used to set the preload value. And transmit the value to the feedback processing unit via the network; The feedback calculation unit calculates the preload value according to the set preload value. Calculate the standard tightening force value The value is then transmitted to the controller via the network. The calculation formula is as follows: ;In the formula, Indicates the standard tightening force value. Indicates the preload value. Indicates the coefficient of friction. The cross-sectional area of ​​the bolt is represented, and the coefficient of friction and cross-sectional area are obtained from the bolt material data table; The controller is based on the standard tension value transmitted by the feedback processing unit. Control and adjust the pressure of the hydraulic pump; The hydraulic pump is an electro-hydraulic servo system, which is used to control the operation of the ultrasonic hydraulic wrench. A workbench is located around the bolt, and an ultrasonic sensor is mounted on the workbench. The ultrasonic sensor is used to measure and calculate the axial preload of the bolt in real time during the bolt tightening process. This value is then fed back to the electro-hydraulic servo system to tighten the bolts; The electro-hydraulic servo system is based on the bolt axial preload. The value is controlled by the ultrasonic hydraulic wrench to tighten the bolts; The ultrasonic force measuring unit is used to measure the force output by the ultrasonic hydraulic wrench, including the tensile force during tightening. With compressive force .

2. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 1, characterized in that: The parameter adjustment panel uses an LCD screen, allowing operators to input preload values ​​via a visual interface. set up.

3. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 1, characterized in that: The controller is based on the standard tension value transmitted by the feedback processing unit. The pressure of the hydraulic pump is controlled and adjusted using the following method: The hydraulic pump calculates and adjusts its output pressure based on the control strategy within its control algorithm. This algorithm is a... The controller is used to adjust the pressure output of the hydraulic pump based on system feedback.

4. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 3, characterized in that: The hydraulic pump is an electro-hydraulic servo system, which is a system that combines electrical and hydraulic control technologies to achieve precise position, speed and force control. By controlling the electric motor to drive the hydraulic pump, the movement of the hydraulic actuator is controlled, thereby achieving precise positioning, motion control and force control of the mechanical system.

5. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 1, characterized in that: A workbench is located around the bolt, and an ultrasonic sensor is mounted on the workbench to simultaneously detect the tightness of two or more bolts.

6. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 5, characterized in that: The ultrasonic sensor is used to measure and calculate the axial preload of the bolt in real time during the bolt tightening process. The calculation formula is as follows: ;In the formula, Indicates the axial preload of the bolt. This refers to the bolt preload factor, which depends on the bolt material, thread type, and lubrication conditions. It can be found in relevant standards in bolt design manuals. This indicates the axial tensile force applied to the bolt; this value is automatically obtained by the system.

7. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 4, characterized in that: The electro-hydraulic servo system is based on the bolt axial preload. The value is controlled by an ultrasonic hydraulic wrench to tighten the bolts. The tightening process is as follows: Based on the measured axial preload The tightening torque output of the ultrasonic hydraulic wrench is controlled by an electro-hydraulic servo system. During the tightening process, the system monitors the axial preload of the bolt in real time and adjusts the torque according to the preset preload value. Adjust the output of the hydraulic system to ensure that the bolts are tightened to the set preload level.

8. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 1, characterized in that: The ultrasonic force measuring unit is used to measure the tensile force output by the ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: ;In the formula, This indicates the tensile force output by the ultrasonic hydraulic wrench during tightening. This indicates the tightening pressure output by the ultrasonic hydraulic wrench; this value is automatically obtained by the system. This represents the effective force-measuring area of ​​the ultrasonic force-measuring unit, and the formula for calculating this area is: , The radius of the hole for all bolts being tightened. This indicates the initial preload value.

9. The multi-channel intelligent ultrasonic hydraulic wrench fastening system according to claim 8, characterized in that: The ultrasonic force measuring unit is used to measure the compressive force output by the ultrasonic hydraulic wrench during tightening. The calculation formula is as follows: ;In the formula, This indicates the compressive force output by the ultrasonic hydraulic wrench during tightening. , This indicates the weight of the bolts that the hydraulic wrench needs to tighten. This indicates the cross-sectional area of ​​the fastening bolt.

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